Secification For Clad Carbon Steel Bends Manufactured by Induction Heating

IMPORTANT NOTE:
DO NOT FORGET TO FILL IN THE

SUMMARY INFO AFTER DOING A FILE
SAVE AS TO AID IN EASY FILE LOCATION.
NAM CON SON GAS PROJECT

LAN TAY/LAN DO, BLOCK 06.1
SPECIFICATION FOR CLAD CARBON STEEL BENDS

MANUFACTURED BY INDUCTION HEATING
DOCUMENT NO: 8381-2302-SV-0006

LIFE CYCLE CODE: B
C3
C2
C1
B1
A1
Rev
No
30/4/2001
6/12/2000
27/6/2000
2/3/2000
14/2/2000
Date
Re-approved for Purchase

Re-approved for Purchase
Approved for Purchase
Approved for Enquiry
Issued for Review
Purpose of Issue
ALS
AL
AL
RCP
AL
Prepared
By
SML
DS
GC
GC
GC
Checked
By
MK
MK
RCP
RCP
EK
Discipline
Approval
EK
EK
EK
EK
Project
Approval

CALCULATION BOOK CHECKLIST
SUBJECT: NAM CON SON GAS PROJECT
JOB NO.: 031692.01
TITLE:
SPECIFICATION FOR THE CLAD CARBON STEEL BENDS MANUFACTURED BY
INDUCTION HEATING
NUMBER: 8381-2302-SV-0006
ISSUE/REVISION: C3
CHECKLIST
ORIGINATOR CHECKER
P.E
T.A
NUMERICAL ACCURACY
( )
( )
TITLE SHEETS
( )
( )
( )
REFERENCES (INC. REVISIONS)
( )
( )
( )
( )
CONTENTS FORMAT
( )
( )
( )
( )
INTRODUCTION
( )
( )
SUMMARY
( )
( )
ASSUMPTIONS
( )
( )
LEGIBILITY
( )
( )
( )
DIAGRAMS CLEAR
( )
( )
( )
UNITS
( )
( )
TABLES CLEAR AND COMPLETE
( )
( )
STRESS LOADS AND SUMMARIES
( )
( )
SHEET HEADINGS (INC. CHECK SIGNATURE)
( )
( )
REFERENCED DOCUMENTS CHECKED
( )
( )
DRAWING CONSISTENCY
( )
( )
SHEET NUMBERING
( )
( )
DESIGN PREMISE COMPLIANCE
( )
( )
( )
COMPUTER OUTPUT ATTACHED
( )
( )
( )
CHECK COPY CORRECT

SIGNED
( )
_____________________
ORIGINATOR
Rev. C3
( )
( )
( )
( )
( )
( )
( )
______________________
CHECKER
Document No: 8381-2302-SV-0006
( )
T.A COORDINATOR
___________________
PROJECT ENGINEER
( )

CONTENTS
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
INTRODUCTION
SCOPE
DEFINITIONS
UNITS
LANGUAGE
ABBREVIATIONS
HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS
QUALITY ASSURANCE REQUIREMENTS
4
4
4
4
4
4
6
7
2.0
2.1
2.2
2.3
REFERENCES
PROJECT SPECIFICATIONS
CODES AND STANDARDS
CONFLICTS
8
8
8
8
3.0
3.1
3.2
GENERAL
MANUFACTURING AND MATERIALS
INFORMATION PRIOR TO CONTRACT AWARD
9
9
9
4.0
4.1
4.2
4.3
4.4
FORMING OF BENDS
GENERAL
CONTROL OF HEAT INPUT
POST BENDING HEAT TREATMENT
END BEVELS
10
10
10
10
10
5.0
5.1
5.2
5.3
5.4
MECHANICAL TESTING OF TRIAL-AND PRODUCTION BENDS

GENERAL
TRIAL BENDS TESTING
PRODUCTION BENDS TESTING
RECORDING
11
11
11
11
11
6.0
6.1
6.2
INSPECTION AND TESTING

GENERAL
METHODS AND EXTENT OF NDT
12
12
12
7.0
7.1
7.2
7.3
7.4
7.5
DIMENSIONS AND TOLERANCES

GENERAL
MINIMUM BEND RADIUS
STRAIGHT LENGTH OF ENDS
TOLERANCES FOR BEND ENDS
DIMENSIONAL SURVEY FOLLOWING BENDING
14
14
14
14
14
15
8.0
DOCUMENTATION AND MARKING
16
Rev. C3
Page 2 of 17

CONTENTS
9.0
APPENDIX
17
APPENDIX A TYPICAL CENTRE TO END DIMENSIONS OF FORMED BENDS
Rev. C3
Page 3 of 17

1.0
INTRODUCTION
1.1 SCOPE
This Specification defines the minimum technical requirements for the manufacture and
inspection of clad carbon steel bends for offshore flowline/riser/tie-in spool sections of
the Nam Con Son Gas Project (NCSGP).
It shall be read in conjunction with the following documents:
DNV 96 Rules for Submarine Pipeline Systems;
DNV 96 Amendments and Corrections May 1998.
This Specification is written assuming that the Contractor will manufacture its own
material in accordance with the applicable specifications and Material Data Sheet
(MDS) for the bends shown on Table 1.1. A diagram of typical centre to end
dimensions of formed bends is shown in Appendix A.
The pipe bends supplied shall meet all requirements of chemical compositions, material
properties, mechanical tests, non destructive testing, repair, hydrostatic testing,
marking and coating, and inspection given in the reference standard.
This Specification covers tubulars with a maximum wall thickness of 45 mm. Where
the purchase order states greater thickness supplementary requirements may apply.
1.2 DEFINITIONS
Contractor shall mean the party to which the Contract is awarded and who shall remain
responsible for conformity to specified requirements of all the product including the
supplied items and services, including those of its sub suppliers.
1.3 UNITS
The International System of Units (S.I) shall be used.
1.4 LANGUAGE
All documentation and correspondence shall be in the English language.
1.5 ABBREVIATIONS
API
American Petroleum Institute
ASNT
American Society of Non-Destructive Testing
BoT
Bends off-plane Tolerance
Rev. C3
Page 4 of 17

Table 1.1
CLAD LINEPIPE BENDS DATA SHEET (1)
Clad
Bend
16.75
Steel/Clad
Grade
SAWL-I450-F/D /
Alloy 625
ID nom
(mm)
383.5
WT min
(mm)
20.0 CS
2.5 Clad
Radius
(mm)
5xODNOM
16.75
SAWL-I450-F/D /
Alloy 625
383.5
20.0 CS
2.5 Clad
5xODNOM
12
SAWL-I450-F/D /
Alloy 625
299.9
20.0 CS
2.5 Clad
5xODNOM
Note:
(1)
(2)
(3)
(4)
Bend
Data
Sheet
No.
5/2,6/3
Bend
Angle
(deg) (3)
No.
Description
90
5/1,6/2
40
6/1
34
Spool pieces
Bends
(Lan Tay
Platform and
Manifold)
4/6
4/5
4/4
4/3
4/2
4/1
7/5
7/3
7/4
7/2
7/1
90
73
42
37
31
6
90
29
36
26
21
4
1
1
1
1
1
2
1
1
1
1
Transported
Fluid
Service
(2)
Design
Press.
(barg)
Hydro
Test
Press.
(barg)
Design
Temp.
(oC)
Gas/
Condensate/
Water
Sour
172
420
-10/+90
API 5L
End Bevel
[HOLD]
Lan Tay Riser

Bends
Gas/
Condensate/
Water
Sour
172
420
-10/+80
API 5L
End Bevel
[HOLD]
Lan Do Riser
Bends
Gas/
Condensate/
Water
Sour
153.8
527
-10/+80
API 5L
End Bevel
[HOLD]
Included for guidance only, correct at time of issue. For final quantities refer to bend data sheets.
Service is according to NACE MR-0175 for cladding only.
For bend angle convention refer to Appendix A.
Due to wall thickness reductions during bending mother pipe wall thicknesses are selected as 24.0 mm CS / 3.0 mm Clad. Bend Supplier shall
confirm final thicknesses to ensure specified bend minimum wall thicknesses are achieved.
Rev. C3
Page 5 of 17
Bevel
Config.

BP
BP Vietnam
CTOD
Crack Tip Opening Displacement
ND
Nominal Diameter
DNV
Det Norske Veritas
DWTT
Drop Weight Tear Testing
ID
Internal Diameter
ISO
International Standard Organisation
MDS
Material Data Sheet
MPQT
Manufacturing Procedure Qualification Test
NACE
National Association of Corrosion Engineers
NCSP
Nam Con Son Pipeline
NDT
Non Destructive Testing
OD
Outside Diameter
PHSER
Project Health, Safety and Environmental Review
RP
Recommended Practice
SAWL
Submerged Arc Welded Longitudinal
SI
International System of Units
SSCC
Sulphide Stress Corrosion Cracking
SSIV
Subsea Isolation Valve
UT
Ultrasonic
WT
Wall Thickness
1.6 HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS

All activities performed during manufacture of clad carbon steel bends manufactured
by induction heating for pipelines shall comply with all applicable Health, Safety and
Environmental Regulations.
1.7 QUALITY ASSURANCE REQUIREMENTS
The Contractor shall work to a recognised quality assurance system in accordance with
ISO 9001, the Contract and the Project Quality Specification.
Rev. C3
Page 6 of 17

2.0 REFERENCES
2.1
2.2
2.3
PROJECT SPECIFICATIONS
8381-2300-AV-0001
Flowline Design Basis
8381-2300-AV-0002
Riser and SSIV Design Basis
8381-2300-RV-0008
Flowline and Umbilical System Description
8381-2302-SV-0004
Specification for Manufacture of Clad Linepipe Equivalent to

SAWL-I-450F/D
8381-4000-SW-0005
Mechanical Testing and Corrosion Testing
8381-4000-SW-0013
Technical Integrity, Documentation and Pipe Tracking

Requirements for Linepipe Contractor (SAW Linepipe)
8381-4000-SW-0027
Linepipe HSE Requirements Specification
8382-3100-SW-0022
Specification for Purchase Welded Linepipe-Ferritic Steel
HC/UPS/M/1/4/1-0001
Lan Tay/Lan Do, Block 06.1 Statement of Requirements
CODES AND STANDARDS

API 5L
Specification for Linepipe
ASME V
Non Destructive Testing
ASNT SNT-TC-1A
Personal Qualification and Certification in Non-Destructive

Testing
ASTM A264
Stainless Chromium-Nickel Steel Clad Plate, Sheet and Strip
ASTM A578
Straight Beam Ultrasonic Examination of Plain Carbon and

Clad Steel Plate for Special Applications
DNV 96
Rules for Submarine Pipeline Systems 1996/Amendments and

Corrections May 1998
ISO 9001
Quality Systems
CONFLICTS
In the event of conflict, inconsistency or ambiguity between the Contract, this
Specification, Statutory requirements, codes and standards referenced in this
Specification or any other documents, the Contractor shall refer to BP, whose decision
shall prevail and be binding.
Rev. C3
Page 7 of 17

3.0
GENERAL
3.1
MANUFACTURING AND MATERIALS

Pipe for bends shall be manufactured from material complying with the requirements of
Clad Pipe Specification 8381-2302-SV-0004 and other referenced standards.
The chemical composition can be modified, if necessary, to meet the mechanical
property requirements after agreement by BP.
The Contractor shall submit the material test certificates for review and acceptance by
BP prior to commencement of production bending.
3.2
INFORMATION PRIOR TO CONTRACT AWARD

The Contractor shall submit the following documentation for review and acceptance by
BP at the bid stage:
a)
Typical Manufacturing Procedure Specification (MPS) including methods of

controlling and monitoring temperatures, heat treatment procedures, and NDT
procedures.
b)
Inspection and Test Plan (ITP).
c)
Initial diameter and wall thickness of mother pipe.
d)
Quality Plan.
e)
Typical Manufacturing Procedure Qualification Records.
Once accepted, these procedures shall not be altered without the written Approval of
BP.
Rev. C3
Page 8 of 17

4.0
FORMING OF BENDS
4.1
GENERAL
Bends shall be produced by induction heating.
During bending, pipe should be oriented such that the maximum thinning occurs on the
thickest wall.
Welded pipe shall be oriented such that the longitudinal weld seam is located at the
neutral axis of the bend.
Procedures established on the MPQT bend shall be fixed for the successive production
bends.
4.2
CONTROL OF HEAT INPUT

Induction bending shall be carried out in temperature range 850oC to 1060oC.
The whole pipe length, both bends and tangential ends, shall be subject to the same
induction heating cycle and post bending heat treatment unless Agreed otherwise by
BP.
The temperature shall be controlled with a permanent installed instrument which is
calibrated against a thermocoupled instrument.
The temperature shall be recorded by chart recorder.
4.3
POST BENDING HEAT TREATMENT

All bends shall receive a final heat treatment to achieve the mechanical properties
stated in Section 6 of this Specification unless otherwise Approved by BP.
Details of the Contractor heat treatment shall be supplied to BP for Acceptance, as
required by Section 3.2.
If the Contractor can demonstrate that the mechanical properties will be obtained
without post bending heat treatment, BP may accept to delete this heat treatment.
However, when bends are not fully heat treated after bending, additional mechanical
testing of the tangent ends and transition zones between tangent ends and induction
heated part of the bends may be required. Precise scope of testing will be Agreed
between Contractor and BP prior to production bending.
4.4
END BEVELS
End bevels shall be supplied in accordance with the standard API 5L specification with
a root face of 1.5 0.5 mm with a bevel angle of 30o, -0o, +5o (HOLD).
Rev. C3
Page 9 of 17

5.0
MECHANICAL TESTING OF TRIAL AND PRODUCTION BENDS
5.1
GENERAL
A Manufacturing Procedure Qualification Test (MPQT) shall be carried out in
accordance with the requirements of this Specification and shall be subjected to
mechanical tests as specified in Section 5.2. Test specimens shall be removed from the
trial bends after the final heat treatment has been carried out.
For each heat treatment, pipe diameter and maximum thickness, a trial bend length of
the tightest bend radius shall be destructively tested.
5.2
TRIAL BENDS TESTING

All mechanical testing and examinations are to be performed in accordance with DNV
96, Appendix B and the requirements of Clad Linepipe Specification 8381-2302-SV0004.
CTOD testing shall not be required.
SSCC testing shall not be required.
Strain age testing shall not be required.
DWTT shall not be required.
In addition, it shall be confirmed that the minimum thickness of the clad layer after
bending is greater than 2.5mm. The minimum thickness of the clad should be
confirmed by measurement at the outer surface of the bend at the point of maximum
deformation.
5.3
PRODUCTION BENDS TESTING

Mechanical testing of production bends will be required if the number of bends
produced from one heat exceeds 50.
5.4
RECORDING
Data from dimension measurements and data from mechanical testing of production
bends and trial bends shall be properly recorded and presented in the form of an asbuilt drawing for each individual bend.
Rev. C3
Page 10 of 17

6.0
INSPECTION AND TESTING
6.1
GENERAL
BP will have access to the Works at all time during which Work is in progress and shall
be at liberty to inspect the manufactured items at any stage and to reject any part not
complying with this Specification.
Each part of the Work shall be inspected by the Contractor during manufacture.
Sufficient inspections shall be made by the Contractor to ensure that the materials,
manufactured items and testing comply in all respects with the requirements of this
Specification.
Requirements for personnel, methods, equipment, procedures and acceptance criteria
for NDT are given in reference standards.
The qualification and competence of NDT personnel used by the Contractor shall be
qualified to ASNT Recommended Practice SNT-TC-1A Level II as a minimum.
Before any production bending, dimensional surveys or mechanical testing is carried
out, BP shall be notified to enable its representative to witness the tests. Such
notification shall be given at least 48 hours before the tests are to be performed.
The results of all dimensional surveys, non-destructive and mechanical testing carried
out shall be recorded by the Contractor and witnessed by BP.
Non-destructive testing shall be carried out following final heat treatment.
Motherpipe shall be hydrostatically tested according to DNV 96, Section 6 E1100.
6.2
METHODS AND EXTENT OF NDT

The NDT is in addition to 100% ultrasonic testing of the bend body, also to include
100% radiographic testing of the weld seam.
Methods, procedures, calibration standards and acceptance criteria shall be in
accordance with the applicable reference standard DNV 96 and the Clad Linepipe
Specification 8381-2302-SV-0004.
6.2.1 Visual Examination
The visual examination is to include 100% of external and accessible parts of
internal surfaces. All bends are to be free from cracks, gouges, dents, grooves,
wrinkles, bulges, kinks and surface spalling.
Gouges or grooves which do occur may, at BPs discretion, be removed by
grinding providing that the resulting wall thickness is within the tolerances for
both carbon steel and cladding.
Gouges or grooves too large for grinding, dents or any other defect listed
above shall be cause for the rejection of the bend.
Rev. C3
Page 11 of 17

6.2.2 Magnetic Particle Inspection or Dye Penetrant Inspection
For carbon steel, all external surfaces, including bevel ends, for bends shall be
100% externally examined by magnetic particle inspection. The Contractors
procedure and the acceptance levels shall be in accordance with the Clad
Linepipe Specification 8381-2302-SV-0004. All accessible surfaces of clad
lining shall be subject to Dye Penetrant Inspection in accordance with ASME V
Art. 6.
6.2.3 Ultrasonic Testing
After bevelling, a minimum of 50 mm at each bend end shall be examined for
laminar imperfections and longitudinal and/or transverse imperfections in
accordance with DNV 96, Appendix D.
Calibration standard and acceptance levels shall be in accordance with
applicable specifications and MDS.
After bending, the bond integrity between the carbon steel and cladding shall be
confirmed in accordance with Clad Linepipe Specification 8381-2302-SV0004. UT examination shall be performed on the bonding in accordance with
Clad Linepipe Specification 8381-2303-SV-0004, Section 4.3.
Rev. C3
Page 12 of 17

7.0
DIMENSIONS AND TOLERANCES
7.1
GENERAL
The wall thickness is not to be below the minimum specified for the Pipeline section.
Dimensional control is to include:
ID at bend ends;
OD for bend body;
Passing of pig gauge consisting of two metal plates of diameter 97% of nominal ID
fixed rigidly at a distance of 1.5 x ID;
Wall thickness measurements;
Out-of roundness, bend ends and body;
Bend radius;
Bend angle;
Linear straightness;
Location of weld seam;
End squareness.
Dimensional controls tolerance checks and thickness measurements shall be made after
final heat treatment.
7.2
MINIMUM BEND RADIUS

Normal bending radius will be 5 x D. For special applications, a radius of 3 x D may be
required.
Inside bend diameter (ID) will be the ruling dimension for welded (SAWL) pipes.
7.3
STRAIGHT LENGTH OF ENDS

The straight length of bend ends, or tangent lengths, shall be a minimum of 500 mm,
unless otherwise Agreed.
7.4
TOLERANCES FOR BEND ENDS

The tolerances on bend ends shall meet the requirements of Clad Linepipe
Specification 8381-2302-SV-0004 for pipe ends in order to comply with the pipe end
tolerances.
Rev. C3
Page 13 of 17

7.5
DIMENSIONAL SURVEY FOLLOWING BENDING
Wall thickness measurement shall be taken using a suitable ultrasonic procedure at

six uniformly spaced points around the circumference at a distance of 1 OD along
the extrados of the bend. Starting within 100 mm from one bend end and ending
within 500 mm from the other bend end.
The minimum wall thickness of bends shall not be less than the minimum wall
thickness specified on the MDS contained in Table 1.1.
The radius of curvature of the bend shall be correct to within:

+ 1% of nominal radius
The included angle between the centrelines of the straight portions at the end of the
bend shall be accurate to within:
+ 0.75o
The ends of the bends shall be machined perpendicular to the longitudinal axis of
the bend. The maximum deviation, as measured with a square, shall be 1.5 mm.
The out-of-roundness of the bend ends shall be controlled on each bend. The body
may be controlled on a random basis, but not less than three times per working
shift during bend production using a pig gauge.
A Pig Gauge, as specified in Section 7.1 above, is to be passed through each bend
after final heat treatment.
The Pig shall consist of a gauge plate with diameter 97% of nominal ID and shall
be guided through the bend with the gauge plate centred and perpendicular to the
longitudinal axis of the bend. The Pig Gauge must show no sign of resistance when
being pulled through the bend. The results have to be recorded and reported for
each bend. A procedure, including drawing, must be submitted to BP for Approval.
Bends off-plane tolerance (BoT) shall be:

BoT
(Bend Angle/90) x 6mm,
Rev. C3
maximum 6mm
Page 14 of 17

8.0
DOCUMENTATION AND MARKING

Documentation and marking shall be in accordance with Project Specification 83814000-SW-0013.
Rev. C3
Page 15 of 17

9.0
APPENDIX A
APPENDIX
TYPICAL CENTRE TO END DIMENSIONS OF FORMED BENDS
Rev. C3
Page 16 of 17

APPENDIX A
Rev. C3
Appendix A

Nominal centre to end dimension, B =

Where
bend radius
bend angle
R tan (a/2)
Rev. C3
Appendix A

Secification For Clad Carbon Steel Bends Manufactured by Induction Heating

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Secification For Clad Carbon Steel Bends Manufactured by Induction Heating

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IMPORTANT NOTE:

DO NOT FORGET TO FILL IN THE

NAM CON SON GAS PROJECT

SPECIFICATION FOR CLAD CARBON STEEL BENDS

DOCUMENT NO: 8381-2302-SV-0006

Re-approved for Purchase

SPECIFICATION FOR CLAD CARBON STEEL BENDS

REFERENCES (INC. REVISIONS)

TABLES CLEAR AND COMPLETE

STRESS LOADS AND SUMMARIES

SHEET HEADINGS (INC. CHECK SIGNATURE)

REFERENCED DOCUMENTS CHECKED

DESIGN PREMISE COMPLIANCE

COMPUTER OUTPUT ATTACHED

CHECK COPY CORRECT

Document No: 8381-2302-SV-0006

SPECIFICATION FOR CLAD CARBON STEEL BENDS

MECHANICAL TESTING OF TRIAL-AND PRODUCTION BENDS

INSPECTION AND TESTING

DIMENSIONS AND TOLERANCES

DOCUMENTATION AND MARKING

Document No: 8381-2302-SV-0006

SPECIFICATION FOR CLAD CARBON STEEL BENDS

APPENDIX A TYPICAL CENTRE TO END DIMENSIONS OF FORMED BENDS

Document No: 8381-2302-SV-0006

SPECIFICATION FOR CLAD CARBON STEEL BENDS

DNV 96 Rules for Submarine Pipeline Systems;

DNV 96 Amendments and Corrections May 1998.

American Petroleum Institute

American Society of Non-Destructive Testing

Bends off-plane Tolerance

Document No: 8381-2302-SV-0006

SPECIFICATION FOR CLAD CARBON STEEL BENDS

Lan Tay Riser

Document No: 8381-2302-SV-0006

SPECIFICATION FOR CLAD CARBON STEEL BENDS

Crack Tip Opening Displacement

Det Norske Veritas

Drop Weight Tear Testing

International Standard Organisation

Material Data Sheet

Manufacturing Procedure Qualification Test

National Association of Corrosion Engineers

Nam Con Son Pipeline

Non Destructive Testing

Project Health, Safety and Environmental Review

Submerged Arc Welded Longitudinal

International System of Units

Sulphide Stress Corrosion Cracking

Subsea Isolation Valve

1.6 HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS

Document No: 8381-2302-SV-0006

SPECIFICATION FOR CLAD CARBON STEEL BENDS

Flowline Design Basis

Riser and SSIV Design Basis

Flowline and Umbilical System Description

Specification for Manufacture of Clad Linepipe Equivalent to

Mechanical Testing and Corrosion Testing

Technical Integrity, Documentation and Pipe Tracking

Linepipe HSE Requirements Specification

Specification for Purchase Welded Linepipe-Ferritic Steel

Lan Tay/Lan Do, Block 06.1 Statement of Requirements