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PLF-PRC-006 - R1 - Procedure For Field Bending
PLF-PRC-006 - R1 - Procedure For Field Bending
MMCEC-MMCOG-SEW JV Revision: 1
MMCEC-MMCOG-SEW JV Revision: 1
TABLE OF CONTENT
1. PURPOSE ...................................................................................................... 3
2. SCOPE .......................................................................................................... 3
3. DEFINITION ................................................................................................. 3
4. RESPONSIBILITY ......................................................................................... 4
5. EXECUTION .................................................................................................. 5
MMCEC-MMCOG-SEW JV Revision: 1
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:
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Additionally, the following reference terms apply to the types of bend utilized on the
pipeline:
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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PETRONAS GAS GRAPHITE-CON-MMSJV-
BERHAD. KTHRO-PLF-PRC-006
MMCEC-MMCOG-SEW JV Revision: 1
5. EXECUTION
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:
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.
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.
5.2.1 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 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
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
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.
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.
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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.
5.3.1 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.
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
5.3.3 Identification
MMCEC-MMCOG-SEW JV Revision: 1
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.
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
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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BERHAD. KTHRO-PLF-PRC-006
MMCEC-MMCOG-SEW JV Revision: 1
Figure 3: Aluminium Gauging Plate for Bending Line Pipe Roundness Inspection
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5.7 Deliverables
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6. RESOURCES
6.1 Personnel
• Supervisor
• Pre-Bending Surveyor
• QC Officer
• HSE Officer
• Bending Machine Operator
• Helper
7. ATTACHMENTS
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ATTACHMENT 1
W.T
PIPE NO. CHAINAGE OBSERVATIONS
NO FACTORY ACTUAL AND LOCATION
HORIONTAL
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ATTACHMENT 2
PIPE DETAIL
Diameter :
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
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ATTACHMENT 3
INSPECTION QC ENGINEER/SUPERVISOR
NAME : NAME :
SİGNED : SİGNED :
DATE : DATE :
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PETRONAS GAS GRAPHITE-CON-MMSJV-
BERHAD. KTHRO-PLF-PRC-006
MMCEC-MMCOG-SEW JV Revision: 1
ATTACHMENT 4
SKETCH :
E1 E2
A A
C D C D
B B
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 :
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
BEND DRIFT
CHAINAGE VIS REMARK
ITEM SIZE PIPE NO. HEAT NO. W.T LENGTH COMB. VER HOR TEST
REMARK :
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