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Doc No:

PETRONAS GAS GRAPHITE-CON-MMSJV-


BERHAD. KTHRO-PLF-PRC-006

MMCEC-MMCOG-SEW JV Revision: 1

ENGINEERING, PROCUREMENT, CONSTRUCTION AND


Page:
COMMISSIONING(EPCC) OF PGU-l GAS PIPELINE REPLACEMENT
PROJECT(GRAPHITE) 1 of 19

PROJECT : ENGINEERING, PROCUREMENT,


CONSTRUCTION & COMMISSIONING
(EPCC) OF PGU-I GAS PIPELINE
REPLACEMENT PROJECT (GRAPHITE)

CLIENT : PETRONAS GAS BERHAD

CONTRACT NO. : PD&T/PGB/2019/326

DOCUMENT TITLE : PROCEDURE FOR FIELD BENDING

1 21/12/2020 FINAL MFH RJN MKAR SRS RKS SMS


Prepared Reviewed Approved Reviewed Endorsed Approved
By by By By By By
Project Construction Project Construction Construction Project
Revision Date Description Engineer Manager Manager Engineer Manager Manager
MMCEC-MMCOG-SEW JV PGB
© 2020 PETROLIAM NASIONAL BERHAD (PETRONAS). All rights reserved. No part of this document may be reproduced, stored in a retrieval
system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of
the copyright OWNER.
Doc No:
PETRONAS GAS GRAPHITE-CON-MMSJV-
BERHAD. KTHRO-PLF-PRC-006

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TABLE OF CONTENT

1. PURPOSE ...................................................................................................... 3

2. SCOPE .......................................................................................................... 3

3. DEFINITION ................................................................................................. 3

4. RESPONSIBILITY ......................................................................................... 4

5. EXECUTION .................................................................................................. 5

5.1 Bending Parameters and Limits .......................................................................... 5


5.1.1 Bend Angle ...................................................................................................... 5
5.1.2 Tangent Ends ................................................................................................... 5
5.2 Bend Qualification Tests .................................................................................... 5
5.2.1 General ........................................................................................................... 5
5.2.2 Test Records .................................................................................................... 6
5.2.3 Bending Machine Operation ............................................................................... 6
5.3 Field Bending ................................................................................................... 8
5.3.1 General ........................................................................................................... 8
5.3.2 Pipe Handling ................................................................................................... 8
5.3.3 Identification ................................................................................................... 9
5.4 Recovery of Pipe from Rejected Bends .............................................................. 10
5.5 Planned and Scheduled Maintenance ................................................................ 10
5.6 Reporting ...................................................................................................... 10
5.6.1 Bend Schedule ............................................................................................... 10
5.6.2 Daily Inspection Report ................................................................................... 10
5.7 Deliverables .................................................................................................. 14
6. RESOURCES .................................................................................................15

6.1 Personnel ...................................................................................................... 15


6.2 Field Equipment ............................................................................................. 15
7. ATTACHMENTS ............................................................................................15

Attachment 1 – Pipe Bending Schedule ....................................................................... 16


Attachment 2 – Bending Qualification Test .................................................................. 17
Attachment 3 – Cut Pipe Report ................................................................................. 18
Attachment 4 – Field Bending Daily Inspection Report .................................................. 19
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1. PURPOSE

The purpose of this procedure is to describe and define the Field Bending activity for
EPCC of PGU-I Gas Pipeline Replacement Project (GRAPHITE). The intent of this
procedure is to act as a guide to personnel engaged in this activity, not supersede or
override any specifications, codes, standards, statutory documents or contract
documents.

2. SCOPE

All field bends (cold bends) required in the installation of the works as described and
defined in the contract documents “scope of work”.

3. DEFINITION

For the purpose of this procedure, the following “definitions” shall apply to descriptive
terms within the text:

COMPANY means PETRONAS Gas Berhad


CONTRACTOR means MMCEC MMCOG SEDIA JV
GRAPHITE means PGU-I Gas Pipeline Replacement Project
Bend means A “change in direction” of the pipe axis within a pipe.
Bend Angle means The “angle” measured between the axis of each end of
the pipe.
Bend Radius means Lines of Intersection normal to the tangent points.
BQT means Bend Qualification Test
Buckling means Severe “deformation” of the surface of the pipe on the
concave side of the bend resulting in the “change in
direction” occurring over a short distance and with the
height of the deformation measured in the pipe radial
direction greater than the length of the deformation
measured in the longitudinal direction.
Compound Bend means A “change in direction” of the axis in two different planes.
Field Cold means The process of achieving a change in direction within
Bending pipe by using a machine specially designed to bend pipe
by a combination of “cold stretching” and “cold
compression” of the pipe, in a controlled manner.
Flat Spot means An area of the “convex side of a bend” where the pipe
surface lies significantly inside a smooth curve around
the girth of the pipe and a flat surface (straight edge)
placed on the pipe can touch the pipe in more than two
places at once.
Neutral Axis means For a simple bend, the location midway between the
stretched and compressed portions of the pipe, that is
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the location on the pipe where no stretching or


compression takes place and contains the longitudinal
weld seam.
Out of means A measure on the “non-circular” nature of the pipe cross
Roundness section.
Ovality means Ovalisation or “out of roundness” of the pipe cross
section generally due to reducing the diameter on one
axis and increasing the diameter on the opposite axis.
ROW means Right of Way
Simple Bend means A “change in direction” of the axis in one direction only.

Additionally, the following reference terms apply to the types of bend utilized on the
pipeline:

OB means Over Bend


SAG means Sag Bend
SBL means Side Bend Left
SBR means Side Bend Right
SBL/OB, means Combination Bends constituting the characteristics of
SBR/OB, two of the preceding bend types
SBR/SAG,
SBL/SAG

4. RESPONSIBILITY

Pre-Bending Surveyor
The Pre-Bending Surveyor shall be responsible for ensuring field bending activities are
conducted in accordance with this procedure. The Pre-Bending Surveyor shall also be
responsible for ensuring the deliverables identified in 5.0 below, are concise clear,
legible and contain sufficient information to provide input into Project Final Records
(data books) and “as-built” drawings.

Superintendent
Superintendent shall be responsible for ensuring the process capability of the bending
machine and associated equipment is maintained by conducting planned and
scheduled maintenance.
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5. EXECUTION

5.1 Bending Parameters and Limits

The limitations and parameters for field cold pulled bends are GRAPHITE-EXE-MMSJV-
KTHRO-PMG-PLN-007 Construction Execution Plan and ITB Exhibit 1, Part III
(Construction), Item 15 - Bending. Key parameters are:

5.1.1 Bend Angle

The specification states that the rate of bending shall not exceed 1.5° per pipe
diameter length. For 36” NPS pipe, this is equivalent to 13.1 Degrees per 8.0m.

5.1.2 Tangent Ends

The Specification states that the pipe shall not be bent within 1.8 metres of the end of
a pipe length i.e. 1.8 metre tangent ends.

5.2 Bend Qualification Tests

5.2.1 General

Prior to site field bending, a “Bend Qualification Test” (BQT) shall be conducted on
each wall thickness of pipe that is to be utilized in the installation of the works.

The “Bend Qualification Test” (BQT) shall be carried out as follows:


For 36” pipe, a full length of pipe will be offered into a suitably sized “bending machine”
and pulled in gradual increments of 0°.20’ per 0.220 m length for a bend angle of
13.1° located at the centre of the pipe.

The Bending Qualification Test pass/fail result (acceptance criteria) will be based on
running a gauging plate with a diameter of 97.5% (as per PTS 11.34.01) of the relevant
wall thickness through the test bend.

Wall thinning will not be recorded, as the pipe wall thickness has been dictated by PGB
to conform to the specification related to bending the pipe in increments of 1.5° per
pipe diameter length. This is the equivalent to 13.1 Degrees per 8.0 meter length of
pipe, whilst remaining within the specified wall thickness tolerance (minimum
thickness after the bend). However, the minimum thinning shall also satisfy as per
AMSE B31.8, Clause 841.11 - Steel Pipe Design Formula below,

2𝑆𝑆𝑆𝑆
𝑃𝑃 = 𝐹𝐹𝐹𝐹𝐹𝐹
𝐷𝐷
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Where,
𝐷𝐷 = nominal outside diameter of pipe, inch
𝐸𝐸 = longitudinal joint factor
𝐹𝐹 = design factor
𝑃𝑃 = design pressure, psig
𝑆𝑆 = specified minimum yield strength, psi
𝑇𝑇 = temperature derating factor
𝑡𝑡 = nominal wall thickness, inch

5.2.2 Test Records

All pertinent information relating to the testing shall be recorded on QAQC doc
(Attachment 2) and shall include the name and I/C number of the operators and serial
number of the bending machine.
The BQT report shall include the following pipe details:
• Wall thickness
• Pipe Number
• Heat Number
• Pipe Manufacturer, and
• Pipe Length
• Type of Bend
• Bend Radius

5.2.3 Bending Machine Operation

The bending machine shall be of a type capable of meeting the requirements of the
“Construction Specifications” with regard to field bending.

There shall be means of observing the hydraulic/air control pressure gauges required
to make the bend on both the bending machine and mandrel.

The bending machine will be fitted with the means of establishing the bend angle at
which the required bend angle is achieved. The stiff back rod will be marked to define
the limit of each pull. This will be determined by the bending operator in charged.

The bending machine will be capable of making the second push at a distance of not
less than 220mm from the first push, to establish the “bend angle” within the
established limits.

The Pre-Bending Surveyor shall make all necessary bends required for the proper
construction of the pipeline, following a trigonometric survey to establish the number
and degree of bends required to ensure that the installed pipe shall conform to the
contours of the pre-padded trench or ground contours.
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The pipeline surveyor will stake out the centre line of the pipeline and will prepare a
detailed pipeline profile.

The Pre-Bending Surveyor analysing the profile will decide the exact location of the
cold and hot bends. During stringing activity, he will mark the pipes which will have to
be bent.

The bending crew will bend the marked pipes using an approved bending machine.

Pipe bending will be undertaken along the pipeline spread. In areas where ground
conditions do not permit the entry of the pipe bending machine bending will be
undertaken in a designated area.

Each pipe should be introduced into the bending machine with the longitudinal weld
placed on the neutral axis surface. One end of the pipe should be placed into the “Pin-
up Shoe” part of the machine with the other end connected to the “Stiff-Back” side.
Contact surfaces of the bending machine shall be padded to prevent damage to the
pipe coating.

The internal mandrel should be located on the stiff back and introduced into the pipe,
where the winch cable is hooked.

The pipe should be positioned using the winch under the “Bending Die” at the point
where the bend should start, and the mandrel is positioned and expanded.

The longitudinal pipe weld seam shall be located on the neutral axis of the bend.

The “Stiff-Back” should be raised simultaneously with the “Pin-Up Shoe” and the pipe
should be brought into contact with the “Bending Die” making sure that the distance
between the end of the “Bending Die” and the top of the pipe is the same.

At this point the “Pin-Up Clamp” closes automatically.

To accomplish the bend, the “Stiff-Back” should be raised further to a predetermined


point on the “Stiff-Back” lifting gauge rod; this action should be completed in one
movement.

The “Stiff-Back” and the “Pin-Up Shoe” should be lowered and the pipe go on contact
with the rollers, the “Pin-Up Clamp” should be opened automatically, the internal
mandrel should be contracted to its initial position and the pipe should be moved for
“one increment” towards the “Pin-Up” using the winch. This completes the first bending
cycle.

The second cycle is then started.


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At this time the mandrel should be moved to the new position and expanded. The “Pin-
Up Shoe” should be raised to bring the pipe into contact with the “Bending Die”, the
“Pin-Up Clamp” close automatically and the “Stiff-Back” should be raised to complete
the second bend.

The new cycle should be completed, and repeated, until the desired degree of bend
should be achieved.

5.3 Field Bending

5.3.1 General

Bending shall generally be carried out, either along the pipeline, or at the location
where the pipe is to be welded. If this is not possible or impractical, the pipe will be
transported to a central location where it will be bent using an approved type of
bending machine. The bend will then be transported back to the original location for
welding.

Figure 1: Bending Machine

5.3.2 Pipe Handling

All pipe handling required by “bending operations” shall be carried out in such a manner
that prevents damage to the pipe or the coating. The bending shoes, roller and mandrel
will be suitably padded to prevent pipe and coating damage. Prior to each bend being
made the bending machine shoes shall be cleaned.

The pipe will be supported and held securely at all times while it is in the bending
machine.
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The pipe shall be set up in the bending machine so that the longitudinally welded seam
of the pipe is will be in the neutral axis of the bend.

Following bending, pipe shall be placed on padded wooden skids, berms or other means
of support to elevate the pipe from the ground surface, standing water or mud and to
place the pipe in a secure position protected against movement due to rain or
settlement.

The entire “bending operation” shall be conducted in such a manner as not to damage
the internal or external pipe coating.

36” PIPE

36” PIPE

36” PIPE 36” PIPE

Figure 2: Lifting Sketch during Cold Bending

5.3.3 Identification

Prior to commencement of bending, the required “bend dimensions” shall be clearly


marked on the pipe that is to be bent. On completion of bending the bend number
angle shall be clearly remarked on the pipe together with its bend type and orientation.
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5.4 Recovery of Pipe from Rejected Bends

Defects in the pipe shall be “cut-out” and as much straight pipe as possible be
recovered by cutting and re-bevelling. A record of the pipe length that have been
recovered or scrapped will be detailed on the Cut Pipe Report (Attachment 3). All pieces
whether recovered or scrapped shall be clearly marked with the pipe details and length.
A record of such pieces shall be kept by the QC department. The minimum recoverable
length of pipe is 2 metres. PUP pieces shorter than 2 metres shall be identified,
recorded and quarantined.

5.5 Planned and Scheduled Maintenance

The Bending Machine and mandrel shall be maintained by the maintenance department
at the intervals listed on “Bending Machine Maintenance Schedule” (BMMS) The Plant
and Equipment Manager will maintain a log of maintenance activities that have been
carried out.

5.6 Reporting

5.6.1 Bend Schedule

A Bending Schedule (Attachment 1) will be prepared by the Pre-Bending Surveyor,


listing location and details of production bends to be made.

5.6.2 Daily Inspection Report

When bending is carried out, Field Bending Inspection Report (Attachment 4) will be
completed and submitted daily to the COMPANY giving full details of the bends
performed and their acceptability in accordance with the acceptance criteria detailed
in this procedure.
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Figure 3: Aluminium Gauging Plate for Bending Line Pipe Roundness Inspection

Note Description Pipe WT (11.9mm)


1 Line Pipe Grade API 5L X65 PSL2
2 Outer Diameter (mm) NPS36 914mm
3 Inner Diameter (mm) 890.2 mm
4 Gauging Plate Dia. = 97.5% ID (mm) 867.9 mm
5 Gauging Length = 1.0 ID (mm) 890.2 mm
Table 1: Gauging Arrangement
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Figure 4: Pipe Marking

Figure 5: Pipe Placing into the Machine


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Figure 6: Pipe Marking for Bending Steps

Figure 7: Bending Operations


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Figure 8: Calliper Gauge Dimensional Check

Figure 9: Calliper Gauge Dimensional Check

5.7 Deliverables

The following are the deliverables of this procedure:


o Bend Qualification Test Record
o Pipe Bending Schedule
o Field Bending Daily Inspection Report
o Cut Pipe Report
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6. RESOURCES

6.1 Personnel

• Supervisor
• Pre-Bending Surveyor
• QC Officer
• HSE Officer
• Bending Machine Operator
• Helper

6.2 Field Equipment

• Car(s) and 4WD Truck(s)


• Line Pipe Bending Machine
• Bending Mandrel
• Side-Boom(s)
• Excavator(s)
• Fuel
• Lifting Devices (Choker Belt)
• Skids
• Measuring and Monitoring Devices
• Surveying Devices

7. ATTACHMENTS

Attachment 1 – Pipe Bending Schedule

Attachment 2 – Bending Qualification Test

Attachment 3 – Cut Pipe Report

Attachment 4 – Field Bending Daily Inspection Report


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ATTACHMENT 1

PIPE BENDING SCHEDULE


(1 Page)
Form No.:
GRAPHITE-MMSJV-SCH-FM-062
PETRONAS MMCEC-MMCOG-SEW JV
GAS BERHAD ENGINEERING, PROCUREMENT, CONSTRUCTION & COMMISSIONING
Rev. No.: 0
(EPCC) OF PGU-I GAS PIPELINE REPLACEMENT PROJECT (GRAPHITE)

PIPE BENDING SCHEDULE


PIPE DIAMETER: SHEET: PREPARED BY:
START KP: FINISH KP: DATED:
LENGTH BEND
SEQ. VERTICAL

W.T
PIPE NO. CHAINAGE OBSERVATIONS
NO FACTORY ACTUAL AND LOCATION
HORIONTAL

OB Over Bend Distribution:


SAG seg Bend Contractor:
SBR Side Right PGB:
SBL Side Left QR File:
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ATTACHMENT 2

BENDING QUALIFICATION TEST


(1 Page)
Form No.:
PETRONAS GAS GRAPHITE-MMSJV-BQT-
FM-078
BERHAD
MMCEC-MMCOG-SEW JV
ENGINEERING, PROCUREMENT, CONSTRUCTION &
Rev. No.: 0
COMMISSIONING (EPCC) OF PGU-I GAS PIPELINE REPLACEMENT
PROJECT (GRAPHITE)
BENDING QUALIFICATION TEST

Report No. : Page : of Date :

PIPE DETAIL

Manufacturer : Material/Grade : API 5L

Diameter :

Pipe No. : Wall Thickness :

Heat No. : Length :

EQUIPMENT DETAIL
Bending Machine Mandrel Compressor
Manufacturer

Model

Serial No
Remarks

BQT DETAIL

Increment No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Bend Increment
( mm )

Pull measurement
(°)
Total Bend
Degree
Remarks :

PRE-BENDING
QAQC COMPANY’s REP Office Use
SURVEYOR

Signature : Signature : Signature :


Name : Name : Name :
Date : Date : Date :
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ATTACHMENT 3

CUT PIPE REPORT


(1 Page)
Form No.:
PETRONAS GRAPHITE-MMSJV-CPR-FM-079
GAS BERHAD
MMCEC-MMCOG-SEW JV
ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING (EPCC) PGU-I GAS PIPELINE
Rev. No.: 0
REPLACEMENT (GRAPHITE)

CUT PIPE REPORT


Report No :
Date :

ORIGINAL ORİGİNAL NEW PİPE MPI UT


SEC No DİAMETER THICKNESS HEAT NO NEW LENGTH PUP LOCATION/COMMENTS
PIPE No LENGTH Nos (PUP) YES/NO YES/NO

INSPECTION QC ENGINEER/SUPERVISOR
NAME : NAME :
SİGNED : SİGNED :
DATE : DATE :
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ATTACHMENT 4

FIELD BENDING DAILY INSPECTION REPORT


(2 Pages)
Form No.:
GRAPHITE-MMSJV-FBD-FM-080
MMCEC MMCOG - SEW JV Page 1 of 2

ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING (EPCC) OF


PETRONAS Rev. No. 0
GAS BERHAD PGU-I GAS PIPELINE REPLACEMENT PROJECT (GRAPHITE)

FIELD BENDING DAILY INSPECTION REPORT


REPORT NO.: MMSJV-FBDIR-KP DATE:
START: KP TO: KP PAGE:

CHAINAGE BEND DRIFT


VIS REMARK
ITEM SIZE PIPE NO. HEAT NO. W.T LENGTH COMB. VER HOR TEST

SKETCH :
E1 E2
A A

C D C D

B B

OVALITY CHECK OVALITY CHECK

ID ACTUAL ID ACTUAL ID DIFFERENCE ID ACTUAL ID ACTUAL ID DIFFERENCE


A-B C-D ACTUAL A-B C-D ACTUAL

ID AFTER BEND ID AFTER BEND ID DIFFERENCE ID AFTER BEND ID AFTER BEND ID DIFFERENCE
A-B C-D AFTER BEND A-B C-D AFTER BEND

BEND :

REMARK :

Prepared/ Inspected by, Reviewed & Approved by,


CONTRACTOR'S INSPECTOR COMPANY'S INSPECTOR

NAME: NAME:
DATE: DATE:

LEGEND: OB-Over Bend, SAG-Sag Bend, SBL- Side Bend Left, SBR-Side Bend Right, COMB-Combination, VER-Vertical, HOR-Horizontal, ACC-Accepted, REJ-Rejected
Form No.:
GRAPHITE-MMSJV-FBD-FM-080
Page 2 of 2
MMCEC MMCOG - SEW JV

ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING (EPCC) OF


Rev. No. 0
PGU-I GAS PIPELINE REPLACEMENT PROJECT (GRAPHITE)

FIELD BENDING DAILY INSPECTION REPORT


REPORT NO.: MMSJV-FBDIR-KP DATE:
START: KP TO: KP PAGE:

BEND DRIFT
CHAINAGE VIS REMARK
ITEM SIZE PIPE NO. HEAT NO. W.T LENGTH COMB. VER HOR TEST

REMARK :

Prepared/ Inspected by, Reviewed & Approved by,


CONTRACTOR'S INSPECTOR COMPANY'S INSPECTOR

NAME: NAME:
DATE: DATE:

LEGEND: OB-Over Bend, SAG-Sag Bend, SBL- Side Bend Left, SBR-Side Bend Right, COMB-Combination, VER-Vertical, HOR-Horizontal, ACC-Accepted, REJ-Rejected

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