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PPL-SU-4737-F
Hot Induction and Cold Shop Bending
This document is the confidential property of Chevron U.S.A. Inc. and its affiliates. When made available to
any contractor providing services to Chevron U.S.A. Inc. or its affiliates, the contractor’s use of this
document shall be governed by the confidentiality provisions of the applicable contract or bid package.
Without limiting the foregoing, neither the whole nor any part of this document may be disclosed by the
contractor to any third party, other than an affiliate of the contractor that requires this information for
purposes of the contract with the Chevron entity, without the prior written consent of the Chevron entity
that has disclosed this document to the contractor. When requested by Chevron U.S.A. Inc. or its disclosing
affiliate, the contractor must return all copies of this document to the Chevron entity requesting such return
and delete any electronic copies from the contractor’s systems.
Any and all modifications (changes, amendments, etc.) to this document must follow approved
Chevron Engineering Standards governance processes.
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Hot Induction and Cold Shop Bending PPL-SU-4737-F
Summary of Changes
Revised technical content may be marked with change bars in the right margin as directed by Author.
The Author denotes the following technical changes to this revision as detailed below:
n/a
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Hot Induction and Cold Shop Bending PPL-SU-4737-F
Contents
1.0 Scope............................................................................................................................................... 4
2.0 References ...................................................................................................................................... 4
2.1 Owner Documents .............................................................................................................. 4
2.2 Industry Codes and Standards ........................................................................................... 5
2.3 Conflict Resolution .............................................................................................................. 6
3.0 Terminology .................................................................................................................................... 6
3.1 Acronyms ............................................................................................................................ 6
3.2 Definitions ........................................................................................................................... 7
4.0 Information to be Supplied by Purchaser.................................................................................... 8
5.0 General Requirements ................................................................................................................. 10
6.0 Process for Accepting and Qualifying Bending Procedures .................................................. 12
6.1 Bending Procedures.......................................................................................................... 12
6.2 Exemptions From Qualification Testing ............................................................................ 13
6.3 Qualification Bends ........................................................................................................... 13
6.4 Testing of Qualification Bends .......................................................................................... 14
6.5 Bending Group Essential Attributes .................................................................................. 15
7.0 Production of Bends .................................................................................................................... 16
8.0 Hardness Testing of Production Bends .................................................................................... 17
8.1 Non-Sour Service .............................................................................................................. 17
8.2 Sour Service ...................................................................................................................... 18
9.0 Hydrostatic Testing...................................................................................................................... 18
10.0 Dimensional and Nondestructive Examination ........................................................................ 19
11.0 Marking ......................................................................................................................................... 22
12.0 Inspection and Test Plan ............................................................................................................. 23
13.0 Documentation ............................................................................................................................. 24
14.0 Supplemental Requirements for Cold Shop Bending .............................................................. 24
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1.0 Scope
1. This specification provides requirements for hot induction and cold shop bending of the
following types of carbon and low alloy steel pipe:
a. ASME BPVC, Section IX, P1, P3, P4, and P5A pipe.
b. API 5L product specification level (PSL) 2 line pipe.
c. PPL-SU-1050 welded line pipe.
d. PPL-SU-1051 seamless line pipe.
e. CSA Z245.1 line pipe.
f. ISO 3183 line pipe.
g. DNV-OS-F101 line pipe.
h. Internally weld overlaid or roll bonded clad pipe with the backings steel pipe
manufactured to one of the specifications listed above.
2. Electric welded (EW), submerged-arc longitudinal welded (SAWL), or seamless (SMLS)
pipe may be bent according to this specification.
3. The requirements in this specification supplement industry standards and Owner
specifications indicated on data sheet PPL-DS-4737 or purchase order.
4. Mitered and segmentable bends are excluded from the scope of this specification. Contact
Owner’s materials and corrosion team for guidance.
5. This specification is to be accompanied by completed data sheet PPL-DS-4737, per
Section 5.0, item 1.
2.0 References
1. The following documents are referenced herein and are considered part of this specification.
2. Unless other specified in Sections 2.1 or 2.2, use the latest edition of the referenced
documents.
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Hot Induction and Cold Shop Bending PPL-SU-4737-F
SSM-SU-5405 Longitudinal Submerged Arc Welded (SAWL) Line Pipe for Water
Depths 1500 Feet and Greater
SSM-SU-5408 Seamless Line Pipe for Water Depths 1500 Feet and Greater
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3.0 Terminology
3.1 Acronyms
CE Carbon Equivalent
CVD Crest-to-Valley Depth
DN Diametre Nominel (nominal diameter in mm)
EW Electric Welded
HAZ Heat Affected Zone
HFW High Frequency Welded
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Hot Induction and Cold Shop Bending PPL-SU-4737-F
3.2 Definitions
Bend Angle Amount of directional change through the bend by taking into
account bend radius arc length.
Bend Group Bends with similar essential bend variables that share a
qualified manufacturing procedure specification (MPS).
Bending Procedure The manufacturing procedure specification.
Bend Radius Distance from the center of curvature to the centerline axis of
the bent pipe.
Cold Shop Bend Bends manufactured utilizing a hydraulic press and
saddle-shaped dies at room temperature, often filled with water
to prevent ovalization.
Extrados Outer curved section of the bend arc.
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Hot Induction and Cold Shop Bending PPL-SU-4737-F
Induction Bend (Hot Bend) Bends manufactured by heating a narrow band 360-degrees
around a pipe at the point of bending as the pipe is being pushed
through the induction coil at a constant speed. Induction bends
are typically not segmentable and have ovality approaching 3
percent.
Intrados Inner curved section of the bend arc.
Mitered Bend Bends fabricated by cutting pipe ends of straight sections at an
angle and joining the sections together by girth welds. Mitered
bends are excluded from the scope of this specification. Mitered
bends create local stress concentration and can make pigging
and in-line inspection (ILI) operations more difficult. Contact
Owner’s Materials and Corrosion Team for guidance.
Mother Pipe Straight section of pipe from which a bend is made.
Qualification Bend Bend prepared according to the bending procedure in order to
qualify or accept the bending procedure.
Segmentable Bend Bends fabricated utilizing a hot press and form process.
Segmentable bends are typically limited to 1 percent ovality to
accommodate “segments” to be cut in the field or shop and still
allow for proper fit up to mating pipe. Segmentable bends are
excluded from the scope of this specification. Contact Owner’s
Materials and Corrosion Team for guidance.
Test Bend Production bend that is tested to ensure that the manufacturing
is being performed properly.
Transition Zone Areas at the start and stop points of bending. For induction
bends, this includes material that extends from the unheated
mother pipe to the material that has been heated to the full
bending temperature. For cold shop bends, this includes
material that extends from unbent mother pipe to the material
that has been cold worked in the bent portion.
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11. For hot induction bending, the bending shall be performed at a temperature greater than the
upper critical temperature of the material.
a. For hot induction bending, bending of carbon steel shall not occur at metal temperatures
less than 1600°F (870°C) or greater than 2000°F (1090°C).
b. Temperature shall be measured with an optical pyrometer or a contact thermocouple.
12. Hot induction bending shall not be performed if the vanadium content is greater than
0.08 percent.
13. Post-bend heat treatment (tempering) shall be required unless otherwise agreed by Purchaser.
14. Clad induction bends shall meet the following requirements:
a. No circumferential seam welds shall be permitted in the bend assembly.
b. Acceptance criteria shall meet the same requirements as for the supplied mother clad
pipe.
c. All mechanical tests required by this specification shall be performed and documented
unless otherwise accepted by Purchaser.
d. A qualification bend shall be produced and tested for each size, wall thickness, grade
(backing steel pipe), and cladding material.
e. Sizes and wall thicknesses may be grouped to require fewer tests to conserve clad pipe
materials with written acceptance from Purchaser.
f. Corrosion testing of the cladding per ASTM A262 or ASTM G28 shall be performed on
the qualification bend after bending. Unless otherwise specified, the calculated corrosion
rate shall not exceed 0.50 mpy (0.013 mmpy).
g. Each clad bend, as a part of qualification, shall have the inside diameter (ID) surfaces
100 percent liquid penetrant examined by direct or remote visual (camera) to an accepted
procedure prior to completing mechanical testing.
15. Unless otherwise specified, Purchaser shall perform in-plant quality assurance inspection
during bending and of the completed order.
16. Unless otherwise specified in PPL-DS-4737, the ends shall be beveled at
30 degrees with a tolerance of +5 degrees and −0 degrees.
17. Unless otherwise specified in PPL-DS-4737, the residual magnetism shall not exceed
30 gauss.
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c. Section 6.2 regarding exemption from qualification testing shall not apply.
Note: Cold shop bending is preferred over hot induction bending of TMCP pipe.
TMCP pipe is particularly at risk for losing strength due to induction
heating.
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6. Qualification bends shall be heat treated in the same furnace in which the production bend
will be heat treated.
7. Qualification testing specimens shall be removed from the qualification bend after
heat treatment.
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Hot Induction and Cold Shop Bending PPL-SU-4737-F
Equation 1
(𝑃𝑃𝑃𝑃 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑)2
𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝑙𝑡𝑡 𝑓𝑓𝑓𝑓𝑓𝑓 =
𝑇ℎ𝑖𝑖𝑖𝑖𝑖𝑖𝑖 × 𝐵𝐵𝐵𝐵 𝑟𝑟𝑟𝑟𝑟𝑟
Equation 2
Note: Qualification of a higher difficulty factor also qualifies a pipe bend with a lower
difficulty factor, provided the other eight essential attributes are met.
f. For induction bends, changes to the following:
1) Bending machine speed by more than ±0.098 inches/minute (2.5 mm/minute).
2) Bending machine coil power by more than ±5 percent.
3) Bend temperature of greater than ±45°F (25°C).
4) Induction heating frequency by more than ±20 percent.
g. Use of different bending machines.
h. Use of different heating coil design for induction bending.
i. Change in the following:
1) Post-bending heat treatment from tempering to quenching and tempering.
2) Post-bending tempering time exceeding ±15 minutes from the qualified
tempering time.
3) Tempering temperature variation exceeding ±25°F (15°C).
4) Cooling medium (or coolant) temperature variation exceeding ±25°F (15°C).
5) Type of cooling medium.
6) Cooling medium flow rate (or equivalent pressure) variation exceeding 10 percent.
j. Change in cladding material (if applicable).
2. A change to any attribute shall constitute a change in the bending group and shall require a
new qualified bending procedure.
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Note: Wall thinning will occur on the extrados and neutral axis of the bend. The tighter
(smaller) the bend radius, the thinner the extrados of the bend becomes. Bender
should be requested to provide wall thinning information based on experience of
similar pipe materials.
Per ASME B16.49 paragraph 12.3 (“Wall Thickness”) requirement, the bend wall
thickness should not fall below 90 percent of the nominal mating wall thickness
marked on the bend (also specified in Section 10.0, item 5a of this specification).
Equation 3
The bend manufacturer should ensure the mother pipe wall thickness is sufficient to
meet the requirement above, such that
𝑡bend = (1 − max. Wall Thinning Ratio) × 𝑡mother pipe ≥ 90% × 𝑡nominal of mating pipe
Equation 4
6. For SMLS pipe prior to bending, the thickest part of the pipe shall be oriented to the outside,
or extrados, of the bend.
7. Cold pressing following tempering to reduce bend ovality shall not be allowed.
8. Bend angles on intermediate strength carbon steel line pipe bends (ASME P1 or API 5L
PSL 2 Grades B/L245 through X46/L290) may be corrected by locally applied heat (such as
with a rosebud torch).
a. Metal temperature shall be limited to 1200°F (650°C) or the maximum tempering
temperature of the bend per PPL-DS-4737, whichever is lower (measured by
temperature-indicating crayons).
b. Localized heating shall be followed by air cooling.
c. Water cooling shall not be permitted.
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Hot Induction and Cold Shop Bending PPL-SU-4737-F
9. For grades of pipe with CE ≥ 0.35 percent or bends exempt from qualification testing
according to Section 6.2, item 2, the entire length of bends shall be furnace tempered. The
following requirements shall apply:
a. Bends exempt from qualification testing according to Section 6.2, item 2 shall be furnace
tempered at a minimum temperature of 1150°F (620°C).
b. A minimum tempering time of 60 minutes per inch (25.4 mm) of wall thickness shall be
used, with a minimum tempering time of 60 minutes for wall thicknesses less than
1 inch (25.4 mm).
c. Bends that have been produced using a previously qualified procedure shall undergo the
same heat treatment as specified in the qualified procedure according to Section 6.2,
item 3.
1) Tempering temperature shall be controlled to ±25°F (±15°C) of the qualified
temperature.
2) Maximum temperature and time at temperature (time above the minimum specified
tempering temperature) shall be recorded in PPL-DS-4737.
3) Localized heat treatment shall not be acceptable.
10. A minimum of one thermocouple shall be required for each stacked layer of bends, plus one
thermocouple measuring the furnace atmosphere temperature.
a. If production bends are to be stacked for heat treatment, shop furnace and stacking
procedure shall be accepted by Purchaser.
b. Furnace thermocouple charts shall be attached to PPL-DS-4737.
11. Project shall ensure any misalignment or unequal wall thickness between bends and mating
pipe are code compliant. Additional requirements shall be considered for the following:
a. Avoid inadequate weld penetration due to high-low.
b. Ensure unobstructed pigging.
c. Bend end bevel, bend taper, and transition spool.
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𝐷2 + 𝐷4
𝐶𝐶𝐶 = − 𝐷3
2
Equation 5
where:
D2 and D4 = ODs of two adjacent crests
D3 = OD of the intervening valley
1
Figure 1: Crest-to-Valley Depth of Pipe Bends (Courtesy of ISO )
1
©ISO. This material is excerpted from ISO 15590-1:2009 with permission of the American National
Standards Institute (ANSI) on behalf of the International Organization for Standardization (ISO). All
rights reserved.
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4. Ovality greater than 3 percent in the bend area shall not be acceptable, where:
Equation 6
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2
Figure 2: Measurement of Bend Angle and Out-of-Squareness
2
Reprinted from ASME B16.49-2012, by permission of The American Society of Mechanical Engineers.
All rights reserved.
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11.0 Marking
1. Each bend shall be clearly marked by paint stenciling with white paint and minimum
1-inch (25.4-mm)-high letters on the ID of the bend.
2. For pipe that is induction or cold shop bent outside the U.S. that must be permanently marked
to comply with import regulations, low-stress die stamping shall be permitted for the country
of origin marking only.
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13.0 Documentation
1. For all bending groups, the bender shall provide the following:
a. Information shown in the “Record of Bend Qualification Testing” section of
PPL-DS-4737, including those qualified per Section 6.2, item 2 and item 3.
b. Qualification test results per PPL-DS-4737, except bends qualified per Section 6.2,
item 2.
2. For production bends, the bender shall provide the information required by the “Inspection
Record for Production Bends” section of PPL-DS-4737.
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