SOUTH EAST SUMATRA GAS PROJECT FEED

JOB No: 1335

CNOOC South East Sumatra BV

SHOP FABRICATION AND INDUCTION PIPE BENDS

DOCUMENT NUMBER: 028120-SPL-001

REV DATE DESCRIPTION PREP’D CHK’D APP’D CLIENT.

A 20-02-2003 ISSUED FOR INTERNAL REVIEW FPM TM

B 24-02-2003 ISSUED FOR CLIENT REVIEW FPM TM TM

C 11-03-2003 ISSUED FOR FEED FPM

 CNOOC SOUTH EAST SUMATRA BV
SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

PROJECT SPECIFICATION
SHOP FABRICATION AND INDUCTION PIPE BENDS

TABLE OF CONTENTS

Page
1.0 SCOPE 3
2.0 CODES, STANDARDS AND REFERENCES..............................................................................3
3.0 DEFINITIONS...............................................................................................................................3
4.0 MANUFACTURING REQUIREMENTS......................................................................................3
5.0 BENDING PROCEDURE..............................................................................................................4
6.0 BENDING PROCEDURE QUALIFICATION..............................................................................5
7.0 BEND DIMENSIONS AND TOLERANCES................................................................................6
8.0 INSPECTION AND TESTING......................................................................................................7
9.0 PAINTING AND COATING.........................................................................................................9
10.0 SHIPPING AND HANDLING.....................................................................................................10
11.0 QUALITY ASSURANCE............................................................................................................10
12.0 DOCUMENTATION...................................................................................................................11

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 CNOOC SOUTH EAST SUMATRA BV
SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

1.0 SCOPE
This Specification describes the minimum requirements for the fabrication of large radius pipe
bends, formed by the heat induction process.
COMPANY supplied individual Data Sheets and/or Drawings shall be considered an integral part
of this Specification. Any conflicts shall be brought to the immediate attention of the COMPANY.

2.0 CODES, STANDARDS AND REFERENCES

The following documents shall be complied with, unless stated otherwise in this Specification. The
latest editions and revisions of each Code and/or Specification shall apply.
2.1 Project Specifications
028120-SPM-024 Piping Materials & Valves
028120-SPM-026 Protective Coatings Specification
028120-SPL-003 Specification for Linepipe
2.2 Industry Standards and Codes
ANSI B31.3 Chemical Plant and Petroleum Refinery Piping
ANSI B31.4 Liquid Petroleum Transportation Piping Systems
ANSI B31.8 Gas Transmission and Distribution Piping Systems
API 5L Specification for Line Pipe
API RP 5L1 Recommended Practice for Railroad Transportation of Line Pipe
ASME Boiler and Pressure Vessel Code, Section V Nondestructive
Examination
ASTM A370 Mechanical Testing of Steel Products
ASTM E10 Test Method for Brinell Hardness of Metallic Materials
ASTM E18 Test Method for Rockwell Hardness and Rockwell Superficial
Hardness of Metallic Materials
ASTM E23 Notched Bar Impact Testing of Metallic Materials
ASNT SNT-TC-1A Non Destructive Testing – Recommended Practice

3.0 DEFINITIONS
The definitions pertinent to this Specification are contained in document number 028120-ACG-
001.

4.0 MANUFACTURING REQUIREMENTS

4.1 General
All works shall be performed in accordance with CONTRACTOR’s safety manual.
4.1.1 Material
The pipe used for bends shall be seamless, electric resistance welded (ERW) or
submerged arc welded (SAW), API 5L-X52 or API 5L-X60 as shown on the
design Drawing.

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 CNOOC SOUTH EAST SUMATRA BV
SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

4.1.2 Bend Radius

Pipe bends shall have a minimum bend radius equal to five (5) times the nominal
diameter .
4.1.3 Included Angle
The included angle of the pipe bend shall be as described on the design Drawing.
Should a conflict arise between this document and the design Drawing, the design
Drawing shall govern.
4.1.4 Bevelled Ends
Both ends of each bend shall be bevelled for welding unless otherwise noted. Both
ends of each bend shall be protected with metallic end caps as per Project
Specification 028120-SPL-003.
4.1.5 Tangents
All finished bends shall have a minimum straight length from bend tangents to
bevelled ends of 2' - 0" unless otherwise stipulated on the design Drawings, in
which case the design Drawing shall govern.
4.1.6 Bending Procedure
CONTRACTOR shall submit a detailed description and qualification of its bending
procedure for COMPANY's review and approval, prior to fabrication of the bends
(refer to Section 6.0 of this Specification).
4.1.7 Girth Welds
Bends shall contain no girth welds. All bends shall be made on entire pipe joints,
as indicated on the Drawings. No additional material shall be used beyond the
developed arc length of a bend in order to form the bend.
4.2 Induction Bend
Cold worked material may not be used for bends formed via the hot process. All pipe bends
shall be fabricated using the continuous, narrow band, induction bending process.

5.0 BENDING PROCEDURE

5.1 Procedure Qualification
The Contractor shall develop (a) written bending procedure(s) and qualify same to the
requirements of this Specification. Pipe bends produced using the qualified bending
procedures shall meet the dimensional, mechanical and quality requirements of this
Specification.
5.2 Essential Variables
The following parameters are defined as essential variables of the bending process and shall
be documented in the bending procedure. Tolerance limits of the essential variables are also
described below:
 Parent line pipe material grade and heat number: any change in grade or heat number.
 Parent line pipe diameter and wall thickness: any change in nominal values.
 Bending temperature: within +50°F range of temperature qualified.
 Bending speed: within –0.25 to +0.15 ipm (inch per minute) range of speed qualified.
 Cooling method: any change in cooling method or equipment (induction bend only).
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SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

 Cooling medium volume: within +10% of volume qualified (induction bend only).
 R/D factor: from minimum qualified to higher values.
 Postbend heat treatment; within +50°F of temperature qualified, and +0.5 hours of time
at temperature qualified, for subcritical heat treatments.
A bending procedure must be requalified when a change is made in any of the applicable
essential variables beyond the limits indicated in the above.
The pipe shall be loaded into the bending machine such that the thickest quadrant lies in the
outer radius of the bend.
The amount of springback shall be controlled to maintain the dimensional integrity of the
bend to the specified tolerance limits of the bend angle and bend radius.
The bending temperature shall be monitored by optical pyrometer. Temperature monitoring
equipment shall be calibrated daily.
For welded pipe the weld seam shall be orientated along the neutral axis of the bend.

6.0 BENDING PROCEDURE QUALIFICATION

6.1 Procedure Qualification Requirement
CONTRACTOR shall qualify its bending procedure with prototype bends as described in the
following, prior to fabricating production bends. The qualification process ensures that the
production bends will meet required dimensions and tolerances, and achieve mechanical
properties corresponding to those of the straight, unheated, parent pipe.

6.2 Prototype Bends

The bending procedure shall be qualified by producing a prototype bend for each diameter,
wall thickness, steel grade and heat number combination of pipe subject to bending.
6.3 Bend Angle and Radius
The bend angle and the bend radius of the prototype bends shall be the most acute
combination, as shown on the Drawings, for each pipe size. The degree of bends shall be
sufficient to :
 Provide no less than three different segments of different bending temperatures and
bending speeds.
 Provide enough bent material for postbend heat treatment, inspection and destructive
testing.
6.4 Prebend Inspections and Tests
Before fabricating the prototype bends, the following measurements and tests shall be
performed on each of the selected pipes from paragraph 6.3 above:
 Wall thickness measurement, in accordance with paragraph 8.5 of this Specification, in
the segment to be bent, at intervals of one (1) foot (305mm).
 Ovality measurement in accordance with paragraph 8.6, along the entire pipe length, at
intervals of one (1) foot (305mm).
 Hardness test, in accordance with ASTM E10 or E18, run on a coupon cut from the
end of the pipe joint.

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 CNOOC SOUTH EAST SUMATRA BV
SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

 Nondestructive examination, in the form of magnetic particle examination (MP), of

100% of the pipe surface. MP examination is to be conducted per paragraph 8.3 of this
Specification.
6.5 Postbend Inspections and Tests
After bending and postbend heat treatment, the following inspections and tests shall be
conducted on the prototype bends.
 Wall thickness measurement, in accordance with paragraph 8.5 of this Specification, in
the bend segment.
 Ovality measurement, in accordance with paragraph 8.6 of this Specification, along the
entire length of the bend, at intervals of one (1) foot (305mm).
 Hardness test, in accordance with ASTM E10 or E18, at four locations along the
external radius of the bend, and at one location on each of the tangent pieces.
 Tensile tests per Section 4, API 5L. Tensile specimens shall be removed from the
tangent section, external radius surface of bend in area of greatest deformation, internal
radius surface of bend in area of greatest deformation, and transition zone from tangent
section to bend section.
 Charpy impact tests of the bend section, per API 5L, SR5. Charpy impact test
specimens shall be removed from the external radius surface of the bend at the area of
maximum deformation. Required test temperature is +32°F.
 Hydrostatic pressure test in accordance with paragraph 8.10 of this Specification.
6.6 Acceptance Criteria
The dimensions of the prototype bend shall meet the requirements of the Data Sheets,
engineering Drawing and this Specification.
The mechanical properties of the prototype bends shall be in accordance with the pipeline
material specification 028120-SPL-003. In addition the following shall apply.
Notch-toughness 35 ft-lb minimum average.
25 ft-lb minimum for any single specimen.

7.0 BEND DIMENSIONS AND TOLERANCES

7.1 Bend Dimensions
Bends shall have bend angles and bend radii as shown on the Drawings. Radii shall be to the
centerline of the pipe.
Dimensional conformance of all production bends shall be verified by measurements and by
drifting, using a gauging pig or other suitable drift tool.
7.2 Dimensional Tolerances
All bends shall be produced with the following dimensional tolerances:
 Bend Angle: + 0.75°
 Bend Radius: + 1%
 Ovality: 0- 2.5% of the original unbent diameter as measured by the difference
between the maximum and minimum diameters for all pipe sizes.
 Wall Thinning: Wall thickness shall not be reduced by more than 8% of the original
unbent wall thickness for all pipe sizes.
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SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

 Plane of Bend: + 0.01 times the centerline radius.

 Linear Tolerances: + 1/16-inch.
 Cut ends: + 1/16-inch perpendicularity to the longitudinal axis of the pipe.
 Out of roundness (at the pipe ends): + 1.5% of the nominal outside diameter.
The maximum height of any wave-shaped irregularity on the bend surface shall not exceed
0.5% of the nominal outside diameter. Maximum height is measured from two adjoining
crests to the valley between. Any such wave shapes shall blend into the pipe surface in a
gradual manner.

8.0 INSPECTION AND TESTING

8.1 General
COMPANY may, at its option, witness any and all tests included in this Specification and
inspect all finished bends.
CONTRACTOR shall provide mill access for COMPANY's inspectors during set-up,
manufacture, testing, storage and preparation for shipment.
COMPANY may, at its own expense, require additional inspection and testing not included
in this Specification.
Results of all inspections shall be documented, in writing, and submitted to COMPANY for
review and approval.
8.2 Visual Examination
Each and every completed bend shall be subjected to 100% visual examination over its entire
surface for defects.
The completed bend shall be free of cracks, bumps, wrinkles, notches, slivers, sharp
projections, scabs, gouges and/or other defects.
All defects shall be noted in the inspection report, marked with chalk and the bend placed in
a holding area.
8.3 Nondestructive Examination
Each and every completed bend shall be subjected to 100% magnetic particle examination
(MP). MP examination shall be conducted in accordance with Section V, ASME Boiler and
Pressure Vessel Code. The wet fluorescent method shall be used.
The completed bend shall be free of cracks, laps, seams, cold shuts, laminations, porosity,
inclusions, slivers, scabs, notches, gouges and/or other defects.
All defects shall be noted in the inspection report, marked with chalk, and the bend placed in
a holding area.
Personnel performing NDE operations shall be qualified Level II technicians, in accordance
with ASNT SNT-TC-1A.
8.4 Dimensional Inspection
Every completed bend shall be inspected for the following features specified in
paragraphs 8.5 through 8.8:
 Wall thinning.
 Ovality.

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SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

 Drift.
 Bend angle.
 Bend radius.
 Plane of bend.
 Tangent points.
 Tangent lengths.
Bends with dimensions that are found to exceed the tolerance limits specified in Section 6.0
shall be rejected.
8.5 Wall Thickness Measurement
Wall thickness measurements shall be taken by means of an approved pulse echo caliper, D-
meter or other suitable ultrasonic device capable of providing readings to 0.001 inch
(0.025 mm).
The instrument used for wall thickness measurement shall be calibrated each day before use.
Surfaces to be measured shall be free of dirt, grease, scale and other foreign matter. All
surfaces shall be treated, if necessary, in accordance with the instrument Manufacturer's
recommendations.
Thickness measurements shall be taken at the following locations :
 Beginning of bend.
 Quarter bend.
 Half bend.
 Three quarter bend.
 End of bend.
At each of the above locations, thickness measurements shall be taken at four locations
around the circumference, as follows :
 At the inside radius of the bend.
 At the outside radius of the the bend.
 At 90 degrees from the inside radius at the top.
 At 90 degrees from the inside radius at the bottom.
8.6 Ovality Measurement
Ovality measurements shall be taken by means of a suitable size caliper or C-gauge. Ovality
measurements shall be taken at the following locations :
 Front tangent end.
 Beginning of bend.
 Quarter bend.
 Half bend.
 Three quarter bend.
 End of bend.
 Rear tangent end.
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FRONT END ENGINEERING DESIGN

The percentage reduction in ovality shall be calculated in accordance with the following
formula :

x 100
where: Di = Increased outside diameter
Dr = Reduced outside diameter
Do = Original outside diameter
8.7 Drift
The minimum internal diameter of each bend throughout any radial cross-section shall
not be less than 96% of the nominal internal diameter of the bend.
8.8 Other Dimensional Measurements
All other required dimensional measurements for every bend shall be made by the standard
shop floor layout and shall include measurement of the following dimensions :
 Angle of bend.
 Radius of bend.
 Tangent points - front and rear.
 Tangent lengths - front and rear.
 Plane of bend.
The actual angle of the bend shall be calculated by measuring the radius of curvature and the
chord dimension, as follows :
Angle of bend = 2 x arcsin
8.9 Hardness Test
All finished bends shall have the hardness tested on the external surface using the Brinell
(ASTM E-10) or the Rockwell (ASTM E-18) hardness test method. The hardness shall be
measured at four (4) locations; two on the internal radius of the bend and two on the outside
radius of the bend.
8.10 Hydrostatic Pressure Test
The CONTRACTOR shall hydrostatically pressure test each finished pipe bend. The test
pressure shall be sufficient to produce a hoop stress of 90% of the specified minimum yield
strength. Test pressure shall be held for thirty (30) seconds. Leaks or deformation are cause
for rejection.

9.0 PAINTING AND COATING

Each bend shall be cleaned of all excessive scale, both internally and externally, by turbining
(internal), or blasting.
All pipe bends shall be painted in accordance with 028120-SPM-026.

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SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

10.0 SHIPPING AND HANDLING

10.1 Shipping
Unless otherwise approved by COMPANY, shipment shall be done in accordance with
API RP 5L1. CONTRACTOR shall provide, for COMPANY's approval, a description of his
procedures for:
 Inventory control.
 Interim storage.
 Shipping preparation.
 Stacking and handling.
 Loading and unloading.
 Land transportation.
These procedures shall be approved before manufacturing the bends. Unless the bends are
specified in the Data Sheet to be factory coated, bends shall be shipped bare; i.e., free from
lacquer, oils or any other coating.
10.2 Handling
Bends shall be handled and stored in such a manner as to avoid damage.

11.0 QUALITY ASSURANCE

11.1 QA Requirements
CONTRACTOR shall provide quality control practices to ensure compliance with all
specified requirements and good workmanship practices. A Quality Plan shall be submitted
to COMPANY. Review and approval of the Quality Plan by COMPANY is required prior to
production.
The Quality Plan will reference to the specific procedures pertaining to each work activity
contained within CONTRACTOR’s Quality Manual.
11.2 Quality Plan
The Quality Plan shall clearly define CONTRACTOR's quality control practices and shall
include, but not be limited to, the following:
 Organizational chart (actual to be used on this Contract).
 Material control, receipt, marking, storage and handling.
 Bending procedure Specification and qualification, and use of controls.
 Fabrication sequence (control of bending process).
 Machine operator qualification requirements and controls.
 Manufacturing/fabrication quality control requirements, control points, inspection and
examination requirements.
 Dimensional control methods and requirements.
 Mechanical properties control and postbend heat treatment.
 Defect repair approval and controls.
 Complete material traceability system.

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 Quality status marking and control system.

 Metrology (measurement devices, heat treatment and machine control equipment, etc.;
methods for performing calibration and control methods).
 Corrective action methods and procedures.
11.3 Audits
COMPANY may perform audits of CONTRACTOR's quality system and shall be permitted
access by CONTRACTOR to all manufacturing, fabrication and inspection areas at any time
work is being performed for COMPANY.

12.0 DOCUMENTATION
CONTRACTOR shall provide COMPANY with the following documents associated with each
pipe bend:
12.1 Bending Procedures
Bending Procedures, with supporting bending procedure qualification test reports (to be
submitted to COMPANY for review and acceptance, prior to use in production).
12.2 NDE Procedures
Nondestructive examination procedures (to be submitted to COMPANY for review and
approval prior to use in production).
12.3 Heat Treatment Records
Heat treatment reports and charts for postbend heat treatments applied to prototype bends
used in qualification of the bending procedure and all production bends.
12.4 NDE Reports
Nondestructive examination reports.
12.5 Operator Certifications
Current list of certified operators (to be submitted to COMPANY prior to start of
production).
12.6 QC Reports
Quality Control reports showing rejection rates, defect types and corrective actions taken (to
be submitted weekly during production of the pipe bends).
12.7 Marking Procedures
Marking procedures describing the traceability of materials (submitted before production).
12.8 Test Results Reports
Copies of all test results required by this Specification. Copies of test documentation shall
clearly identify the bend by mark number (submitted after production).
12.9 Bend Production List
A master bend production list, which provides the details of the bends produced, such as
bend mark number, repairs, rejects, radiography, etc. This list shall cover the entire bends
order and shall be provided to COMPANY no later than ten (10) days after completion of the
order.

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FRONT END ENGINEERING DESIGN

12.10 Document Format

All documentation shall be supplied in hard copy format, and in electronic format or CD.

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