CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP

SPECIFICATION

INDUCTION BENDS
TO
DNV OS-F101

DOCUMENT NUMBER: 84501-9230-2L-009

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Dean Hewitt

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CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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REVISION CONTROL SHEET

LATEST REV

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COMMENTS

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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TABLE OF CONTENTS

1.

INTRODUCTION ..4

2.

GENERAL BENDING REQUIREMENTS ....5

3.

MATERIALS .....5

4.

MECHANICAL PROPERTIES ...5

5.

INDUCTION BENDING PROCESS ......5

6.

HEAT TREATMENT ....6

7.

MANUFACTURING PROCEDURE SPECIFICATION ...6

8.

NON-DESTRUCTIVE EXAMINATION ..7

9.

DIMENSIONAL TOLERANCES .....8

10.

MARKINGS AND COATINGS ....9

11.

MANUFACTURING PROCEDURE QUALIFICATION TESTS ...10

12.

INSPECTION ...11

13.

SHIPMENT ...12

14.

CONTRACTOR DOCUMENT SUBMITTALS ....12

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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1. INTRODUCTION
1.1 Scope
This document defines minimum quality and technical requirements for
Induction Bends to DNV OS-F101 used in offshore pipelines.
Contractor shall obtain Company written approval for any deviations from the
requirements of this document or specifications, standards and drawings
referenced herein or elsewhere in the Contract.
This document and the codes, specifications and referenced documents listed
in 1.2 below are not intended to be all-inclusive. The requirements set forth
do not relieve Contractor of his responsibility to perform all services in a safe
manner, to meet applicable codes and standards, to comply with government
regulations or to supply a product capable of performing its intended service.
1.2 Codes, Specifications, And References
The latest editions of all applicable codes, specifications and references shall
define the minimum requirements applicable to the subject work and no
statement contained in this Specification shall be construed as limiting the
work to such minimum requirements.
Wherever conflicts or omissions between codes, specifications and contract
occur, the most onerous condition shall apply. Contractor is responsible for
reviewing the list below and informing the Company of any omissions. All
conflicts shall be formally brought to the attention of the Company.
Applicable Codes
ASNT-TC-1A

Personnel Qualification and Certification in Non-destructive

Testing

DNV OS-F101

Submarine Pipeline Systems : 2000

Company Specifications
84501-9230-2L-022

Seamless Flowlines to API 5L

84501-9230-2L-046

Submerged Arc Welded Double Line Pipe to DNV

OS-F101

84501-9230-2L-008

Handling, Storage and Transportation of Line Pipe

84501-9230-2L-042

Clad / Lined Line Pipe

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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2. GENERAL BENDING REQUIREMENTS

2.1 The quantity of line pipe to be formed into bends and any additional Company
requirements shall be specified on the Purchase Order.
3. MATERIALS
3.1 Induction bends manufactured from pre-formed pipe joints shall conform to the
project line pipe specifications listed in Section 1.2.
3.2 Pipe for clad bends shall be manufactured from metallurgically bonded clad pipe.
4. MECHANICAL PROPERTIES
4.1 Mechanical properties of induction bends formed from pipe joints, including
fracture toughness, shall in their final heat-treated condition conform to the
requirements of the applicable specification listed in Section 1.2 above,
except that the Charpy impact energy requirements for the base metal for
SAW pipe are reduced to the longitudinal weld metal values. Supplier shall
certify that all finished components do not exceed 265 Brinell hardness for the
base metal or 280 Vickers (Hv10) for weld cross section measurements for
SAW pipe.
5. INDUCTION BENDING PROCESS
5.1 Induction bends shall be produced in accordance with Manufacturing Procedure
Specifications (MPSs) that are written in accordance with Section 7 of this
specification and qualified in accordance with Section 11 of this specification.
5.2 Induction bends shall only be manufactured from pipe joints produced in
accordance with the Project line pipe specifications listed in Section 1.2.
Bends shall be formed using the incremental induction hot bending technique
over the entire bend. Induction bends from longitudinally welded (Submerged
Arc Welded) pipe shall be formed with longitudinal seams within 10 O of the
bend neutral axis. Supplier shall submit the following items for Company
approval:

Forming Procedure, including width of heated band, bending temperature

range and temperature control methods.

Post-forming Heat Treatment Procedure.

Quality Control Procedures (including non-destructive testing).

5.3 Supplier submitted heat treatment procedures shall specifically describe

attachment of braces or other restraints used to prevent bend warping.
Welding such attachments to the bend body is strictly prohibited. Welds may

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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be made to expendable extensions of the bend that are to be cut off prior to
finishing.
5.4 No stoppage shall be allowed during the bending process.
6. HEAT TREATMENT
6.1 Post bend heat treatment shall be applied as necessary to meet specifications.
Consideration shall be given to the manufacturing process of the pipe (e.g.,
TMCP, Q&T, normalized). When practical the pipe manufacturer should be
involved in the selection of specific pipes to be bent and in advising of post
bend heat treatment conditions if applicable.
6.2 If post bend heat treatment is used, temperature ranges specified in approved
heat treating procedure(s) shall be measured during all heat treatment.
Thermocouples attached to representative bend sections shall confirm actual
metal temperature.
7. MANUFACTURING PROCEDURE SPECIFICATION
7.1 A manufacturing procedure specification (MPS) shall be established for each
grade, pipe size and bending radius in the order. Tests bends and production
bends shall be made in accordance with the procedure. The MPS shall
contain the following items as a minimum:

Sequence of operations.

Equipment to be used.

Position of weld seam.

The MPS for the mother pipe for bends. The mother pipe for bends shall
be made in accordance with project line pipe specifications listed in
Section 1.2, as appropriate.

The pipe benders nomenclature and description of the induction

coil/cooling ring.

The bending temperature plus tolerances.

temperature around pipe during bending.

Water pressure, flow rate (if available), and water temperature.

Method of measuring temperature.

Locations around pipe that
temperature is measured. Method of controlling temperature.

Speed of bending plus tolerance.

If internal cooling ring is used in addition to the external one, the

nomenclature and description of that ring.

Allowable variation of

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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Procedures for starting and stopping the bending process. Providing

details of how the speed is accelerated to the bending speed and how it
is decelerated. The point at which the current to the coil turned on and
off shall be stated. The point at which the water to the cooling coil
turned on and off shall also be stated. The procedure shall clearly
define which steps are done automatically and which ones manually.

Post bending heat treatment procedure including bracing, temperature

plus tolerances, time at temperature, method of cooling from
temperature and method of temperature control within the furnace.

Hydrostatic testing procedure.

Non-destructive testing procedures.

Dimensional control procedures.

Mechanical Properties Test Procedures.

Marking, Coating and Protection Details.

Handling, Loading, Shipping and Preservation Procedure.

8. NON-DESTRUCTIVE EXAMINATION
8.1 All techniques and procedures for Radiography, Magnetic Particle Inspection
(MT), Dye-Penetrant Inspection (PT) and Ultrasonic Testing (UT) to be used
by Supplier shall be submitted in writing to Company for approval prior to
starting production and shall comply with the requirements of DNV OS-F101,
Appendix D. All non-destructive examination shall be performed on bends in
the final heat-treated condition and after hydrostatic testing and shall be in
compliance with one of the appropriate standards listed in DNV OS-F101
Appendix D, Article B100, 2000.
8.2 Technicians performing non-destructive inspection shall be qualified to the
requirements of SNT-TC-1A, Level II.
8.3 Completed induction bends shall be inspected as per DNV OS-F101, Section 7,
G800. Bends shall be free from cracks and other injurious defects. All
bevelled faces shall also meet the above criteria when tested by MT or Dye
Penetrant Inspection (PT) methods.
8.4 All bends shall be subject to one hundred percent (100%) Visual Inspection as
per DNV-OS-F101, Section 7, G800. Acceptance criteria shall be in
accordance with the relevant line pipe specification.
8.5 Minor surface defects shall be removed by grinding provided the remaining wall
thickness is not less than the minimum specified wall thickness and a smooth
transition exists between the ground area and the original contour, i.e. no
stress risers. Defect removal shall be confirmed by MT. Defect removal that

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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results in less than specified minimum wall thickness shall result in bend
rejection.
8.6 Longitudinal surface defects, score marks, etc. shall be investigated by UT
examination, to confirm orientation and depth, and reported to Company prior
to any attempted repair or removal by grinding. Company may at its
discretion reject the bend.
8.7 No weld repairs shall be permitted.
8.8 Surface hardness measurements using an approved hardness tester shall be
performed on all finished bends as per DNV-OS-F101, Section 7, G800, at the
following locations:

Each tangent

Outside of bend

Inside of bend

Each transition area

8.9 Each bend outer radius shall be subject to UT examination for transverse defects
before shipment. This examination shall be made with an angle probe along
a 150-mm band on the outer bend radius. Defects in excess of those
specified the project line pipe specifications listed in Section 1.2, as
appropriate, shall be rejected. Cracks, regardless of depth, shall be rejected.
8.10

Contractor shall subject each bend to a hydrotest in accordance with DNV

OS-F101, Section 6, E1100, except that the holding time shall be two hours.

8.11

All longitudinal weld seams shall be UT inspected over their entire length.
Acceptable limits shall be in accordance with the project line pipe
specifications listed in Section 1.2.

8.12

All linepipe bends, if cut from original pipe delivered length, shall be one
hundred percent (100%) RT examined for the end 300 mm. Acceptance
criteria shall be to DNV OS -F101 Appendix D Table D-4.

9. DIMENSIONAL TOLERANCES
9.1 Dimensional tolerances shall meet the requirements of the relevant line pipe
specification and the following. In case of conflict, the tolerances contained in
this specification shall govern.
9.2 Minimum internal diameter of each bend shall be guaranteed by passing a
gauging plate, consisting of two circular parallel concentric plates, through the
completed bend. Minimum gauging plate thickness shall be 6.0 mm. The
gauging plate shall be required to pass completely through the bend without

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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obstruction. Unless stated otherwise on the Purchase Order, the gauging

plate diameters shall be:

Gauging plate diameter = Ninety-six percent (96%) of nominal internal

diameter (ID)

Minimum distance between gauging plates = 1.5 x ID

9.3 Maximum percent ovality shall be determined by measuring the bend outside
diameter, and is defined as maximum outside diameter minus minimum
outside diameter, divided by nominal pipe diameter and multiplied by 100.
Maximum percent ovality shall not exceed three percent (3%). Ovality at the
ends of each bend shall be equal to nominal inside diameter +/- 5.0 mm i.e.
the inside diameter at the pipe ends (within 100 mm of the pipe end) shall be
within 5.0 mm of nominal as measured with a rod gauge.
9.4 Bend radius shall be measured and shall be within 1% of that specified.
9.5 Angular bend tolerance shall be +/- zero point five degrees (0.50 O), determined
by intersecting tangent centerlines, measured by appropriate equipment.
9.6 Out-of-plane bend angle tolerance shall not exceed 10-mm deviation from a flat
base.
9.7 The inside diameter of each end of each bend shall be measured within 100 mm
of the pipe end and shall meet the tolerance requirement of the appropriate
linepipe specification listed in Section 1.2.
9.8 Bends shall have tangents at both ends with minimum length 1000-mm, unless
noted otherwise in the Purchase Order. Bend ends shall be bevelled in
accordance with the project line pipe specifications listed in Section 1.2, as
appropriate. Where required, tapered transitions shall have minimum one in
four slope. The pipe end face shall be perpendicular with the axis of the pipe
within 1.5 mm as measured with a square.
9.9 Supplier shall not accept pipe for bending of less than nominal wall thickness.
The allowable thickness after bending shall be defined in the Basis of Design
and shall be stated in the Purchase Order. Thicker walled pipe may be
required for bend production to achieve a minimum wall thickness that is
compatible with that of the adjoining pipe.
10. MARKINGS AND COATINGS
10.1

Induction pipe bends shall be paint-stencilled on both inside ends with

Supplier name, material grade, size and wall thickness, bend radius, bend
angle and weight in kilograms. Additionally, the Purchase Order number and
Company project name shall be clearly marked on the bend OD.

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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10.2

Induction bends shall be abrasive blasted to remove loose scale and other
foreign material after all required heat treatment has been performed.

10.3

All induction bends shall be externally coated with a Company approved, high
build, two-pack epoxy or Company approved equivalent.

10.4

All bevelled ends shall be suitably protected against damage during transit.
Ends shall be coated with a weldable primer such as Deoxaluminite, or
Company approved equal, that can be easily removed with solvent and that
will prevent weld preparation rusting for a period of at least twelve (12)
months under exposed field conditions.

11. MANUFACTURING PROCEDURE QUALIFICATION TESTS

At least one qualification test bend shall be made for each pipe diameter
using the heaviest wall thickness for each pipe diameter, strength grade, and
bending procedure to be used. The radius for the test bend shall be that of
the smallest radius bend on the order and it shall contain the same length
tangents as required on production bends. The bend shall be made using the
manufacturing procedure specification. Company acceptance of proposed
manufacturing procedure specification shall be contingent on test results. The
following tests shall be performed on each test bend. The mechanical
properties shall meet the requirements specified in Section 4 of this
specification.
11.1

All non-destructive examinations, dimensional measurements, and surface

hardness tests are required for test bends.

11.2

Additional surface hardness reading shall be taken at four equally spaced

locations around the bend using approved hardness measuring equipment at
the following locations:

11.3

Each tangent

Each transition area

Center of the bend

At least two other locations in the bend area.

UT surveys shall be made on the finished bend to determine wall thickness.

These surveys shall be made along three lines.

Center of bend axis

Inside radius and outside radius of the bend

Neutral axis or weld in case of seam welded bends

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

DOCUMENT NUMBER
84501-9230-2L-009

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Readings shall be spaced no more than 150 mm apart and 50 mm or more

from the ends. Minimum wall thickness at any point shall be at least ninetyfive percent (95%) of nominal wall thickness of connecting pipe joints.
11.4

Mechanical testing shall be performed in accordance with DNV OS-F101,

Section 7, G600, and the following additional requirements:
a.

b.

c.

Tangent area- neutral axis (opposite of weld)

One tensile test from each tangent.
Tangent area- weld
One transverse weld tensile test (tensile strength only) from each
tangent.
One set of Charpy impact tests for each of the following: weld
centerline, HAZ, and base metal.
One micro section with hardnesses across the weld. Hardness
traverses in accordance with those in with the project line pipe
specifications listed in Section 1.2, as appropriate.

Acceptance criteria

Mechanical testing acceptance criteria shall be in accordance

with the relevant line pipe specification and DNV OS-F101,
Section 7, G608.

11.5

The bend is to be subject to one hundred percent (100%) ultrasonic testing of

the bend body. Acceptance criteria in accordance with the project line pipe
specifications listed in Section 1.2, as appropriate.

11.6

The bend weld seam, if applicable, shall be one hundred percent (100%) RT
examined. Acceptance criteria shall be as DNV OS-F101 Appendix D Table D4.

12. INSPECTION
12.1

Supplier shall furnish Company inspectors reasonable facilities and space,

without charge, for inspection, testing and information gathering regarding
work progress and quality for induction bending of pipe joints. Company
inspectors shall have free access to all parts of the plant concerned with the
work.

12.2

Supplier shall notify Company at least three weeks prior to commencement of

production, to allow time for final approval by Company of both manufacturing
and inspection procedures.

12.3

After production has started on the order, Supplier shall notify Company
inspectors at least twenty-four (24) hours in advance of any changes in
production schedules.

CONOCO INDONESIA INC. LTD.

INFRASTRUCTURE GROUP
SPECIFICATION
TITLE
INDUCTION BENDS TO DNV OS-F101

12.4

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Company inspectors shall operate independently of Supplier inspectors.

13. SHIPMENT
13.1

Supplier shall submit for Company approval, when quoting, drawings of

proposed induction bend stacking and shipping methods. Supplier shall
ensure induction bends are located so as to reduce the possibility of critical
stresses and fatigue cracks due to cold working in transit. Bends shall not lay
on longitudinal weld surfaces. Stresses shall be limited so that no additional
bend out-of-roundness can occur during shipment.

13.2

Timber blanks or metal end bevel protectors shall be used to protect end
bevels. Bends shall be lifted and stacked in strict accordance with Project
Specification for Handling, Storage and Transportation of Line Pipe.

14. CONTRACTOR DOCUMENT SUBMITTALS

14.1

14.2

Supplier shall submit to Company for approval the following documents prior
to commencement of work:

Work Procedures & Manufacturing Specification

Procedure Qualification

Shop Drawings

Handling and Packing Procedures

Supplier shall submit to Company for approval a data book containing all
relevant documents including:

Results of Manufacturing Procedure Qualification

Certified NDT Reports

Certified Mechanical Test Reports

Mill Certificates

Results of any special tests required by this specification

Certified Drawings

Storage Procedures

Calibration Certificates

All certificates shall be in the English language and use metric units of
measure.
Supplier and Company Representative shall visibly sign
certificates.