PROJECT : 18”× 30 KM ODJP-KCJP & KJP PIPE LINE PROJECT

CLIENT : M/s. GAIL (INDIA) LIMITED, RAJAHMUNDRY

CONSULTANT : M/s. MECON LIMITED, DELHI
CONTRACTOR :. KIRLOSKAR CONSTRUCTIONS & ENGINEERS LIMITED

PROCEDURE FOR COLD BENDING

SCOPE

This procedure covers the minimum requirement for the fabrication of cold bends.

REFERENCE

MECON Specifications No:- MEC/S/05/62/01 Rev.A.

COLD FIELD BENDING

The radius of the cold field bends will not be less than 40 times the pipe outer diameter for
pipe diameter 18” and above and will not be less than 30 times the pipe nominal diameter for
pipe diameter less than 18”

Method of bending of the coated pipes is in accordance with good pipe line construction
practice. Bends will be made with out any wrinkles, buckles and minimum damage to the
coating.

Bending machine is mechanical type extensively used by Pipe Line Engineers. The
machinery mainly consists of a screw rod nut assembly with die attached at the end and the
supporting shoes in a rigid frame structure, which gives 17mm forward movement for one
full rotation of the screw rod. Dies and shoes of the bending machine will be properly padded
to avoid any damage to the coating during bending.

Pipe with longitudinal welds will be bend in such a way that the weld lies in the plane
passing through the neutral axis of the bend which will be installed positioning the
longitudinal weld in the upper quadrants. If horizontal deviations are to be achieved by
joining more adjacent bends , the bending of the pipe lengths will be made by positioning the
longitudinal welds alternatively 70mm above and below the plane passing through the neutral
axis in such a way that the bends are welded with the longitudinal welds displaced by about
150mm and situated in the upper quadrants. In case of vertical bends formed from a number
of pipe lengths, the longitudinal welds will be positioned on the plane passing through the
neutral axis of the bend to the right and left alternatively.

The ends of each bend length will be straight and not involved any way in bending.
The length of the straight section will permit easy joining In no event the end of the

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bend will be closer than 1.5mtr. from the end of the pipe or with in one meter from
girth weld.
The ovalisation caused on each pipe by bending will be less than 2.5% of the nominal
diameter at any point. A check will be performed on all bends by passing a gauge
consisting two discs with a diameter equal to 95% of the nominal internal dia of the pipe
connected rigidly together at a distance equal to 200mm.

Cold bend pipe on site will be checked for any defects of disbonding of coating caused
during the bending with the aid of a holiday detector. It will also be checked whether the
coating has disbonded form the pipe wall during bending by knocking with a small wooden
mallet along the outer radius. Any defect or disbonding of the coating caused during bending
will be repaired.

ACCEPTANCE CRITERIA

As per MECON Specifications No:- MEC/S/05/62/01RevA.

DOCUMENTATION

Inspection report No: GAIL/MEC/KCEL/ML/06

Inspection & Test Plan No: GAIL/MEC/KCEL/ITP/06

NOTE

The above details are only guidelines for quick reference in the field. Detailed procedure
given in contract specification shall always prevail.

CALCULATION DETAILS OF 45O COLD BEND

Calculation of 45° cold bend (Example)

Length of bend ( L ) : 45 X OD of pipe X 0.01745 X Degree

45 X 114.3 X 0.01745 X 45
3590.163.
Number of punches ( N ) : L / die size = 3590.163/ 270 = 14 nos.

Degree per punch : Degree required / N = 45 / 14 = 3.2 = 3°12’.

A
SUBMITTED FOR
APPROVAL
REV NO DATE PREPARED BY CHECKED BY APPROVED BY

KCEL KCEL MECON

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 GAIL/MEC/KCEL/QCP/06
PROCEDURE FOR COLD BENDING