4.5.

9 Carbon steel Fittings

Fittings for size 24" and below shall be seamless and shall be as per ASME B16.9. For
factory-made fittings larger than size 24” MSS SP-75 shall apply.

4.5.9.1 General Requirements for Pipeline Bends

For horizontal and vertical change of direction in general three (3) types of bends shall be
used:

Type 1:

Factory bends (elbows) with a center-line radius of 1.5 x outside diameter. These bends shall
be furnished with internal cement mortar lining and exernal FBE coating + cold tape
wrapping.

Type 2:

Bends fabricated on site by cutting the pipe end with a bevel machine (Miter bends).

These bends are only permitted up to an angle of max. 3° per joint (cutting of the two pipe
ends in an angle of 1 ½° each.

Type 3:

Field bends, made of standard line pipe. The following requirements are valid for this type of
bend:

 only pipes without lining shall be bent

 bending shall be performed in accordance with the applicable API and ASME regulations

 bending shall be carried out at the yard and under “yard-conditions”

 cement lining shall be performed after bending at the yard and under “yard-conditions”

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 80 of: 136
 4.5.9.2 Factory Bends

Factory-made bends (elbows) shall be used where indicated on the pipeline drawings. Field
bends shall not be used where a hot-formed bend is shown on the Drawings. Requirements
pertaining to factory bends are defined in Section 4.6 of the Specification.

4.5.9.3 Field Bends

Field bends shall be cold formed on an approved bending machine of the correct size with an
internal mandrel. The pipe shall be bent to a minimum radius of 40 x outside radius of the
pipe based on the applicable code.

All field bends shall be of constant radius, uniformly circular in section and free from buckling,
wrinkling, flattening, cracking or any other defect or damage. The pipe diameter shall not be
reduced at any point by more than 2 per cent.

If the pipe has a longitudinal seam, the seam shall be located on the neutral axis.
Longitudinal seams in adjacent joints shall be offset by at least 250 mm at the pipe
circumference. The difference between the maximum and minimum diameters of the bent
pipe due to ovality shall not exceed 2.5 % of the nominal diameter. All bends shall have a
tangential straight no less than 2 meters on each end.

Prior to the start of field bending, a bending procedure test must be carried out by the
CONTRACTOR on each and every pipe size and wall thickness in the presence of the
OWNER. The completed bend shall be ultrasonically checked before and after the test to
ensure that any reduction in wall thickness does not exceed the maximum under thickness
tolerance as specified in API 5L.

Before they are incorporated in the pipeline, all bends shall be checked with a gauging device
fitted with two sizing plates of the min. permitted pipe internal diameter held apart by a
distance of approximately 1 pipe diameter.

Where bends are formed from coated pipe, the coating shall be inspected. Where damage
has occurred, the coating shall be repaired or replaced.

A bend register shall be maintained, which shall indicate the following information:

 The date that the cold bend was pulled

 The bend angle

 The pipe number

 The KP location

4.5.9.4 Flanges

Flange dimensions shall be conforming to BS 4504 Sect 3.1 / ISO 7005 Part 1 and the rating
of the flanges shall be as per the applicable data sheet. All the flanges shall be welding neck

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 81 of: 136
 4.6 Specification for Carbon Steel Bends

4.6.1 Introduction

The proposed pipeline shall be designed and constructed using welded steel line pipes with
three layer polyethylene coating and cement mortar lining, suitable for underground (buried)
installation and transportation of potable water.

This Specification covers the technical requirements for factory-made bends used in the steel
pipeline sections.

4.6.2 Scope and Standards

The butt-welding bends shall generally meet the requirements set out in Standard Practice
SP-75 developed and approved by the Manufacturers' Standardization Society (MSS) of the
Valve and Fittings Industry, latest edition, and the requirements of this Specification.

Technical requirements, including dimensions, of the bends not covered by MSS-SP-75 shall
be calculated I extrapolated by the Contractor for approval by the Owner/Engineer.

4.6.3 Specification and Material

4.6.3.1 Steel

The chemical composition of the mother pipes and mechanical properties of the bend in the
final heat treated condition shall be as per the Specification for Carbon Steel Pipeline.

4.6.3.2 External Coating

The bends shall be externally coated with FBE with minimum DFT of 300 microns as per
coating specification. Application methods deviating from those specified shall be subject to
separate approval by the Owner/Engineer. The FBE layer shall be additionally protected with
cold tape wrapping of minimum thickness of 3.0 mm as per ADWEA Standard Specification
W-P-SS-010 Rev. 2.

4.6.3.3 Internal Lining

The Cement-Mortar Lining shall comply with the specification. The bends shall be internally
lined with cement mortar lining on site.

4.6.4 Bend Design

All bends to be manufactured according to this specification shall have a centerline radius of
R = 1.5 x DA (outer diameter of the matching line pipe).

Pressure design shall be such that the maximum allowable operating pressure is equal or
higher than that of the matching pipe.

In no case the minimum wall thickness and diameter at the bend end bevel shall be less than
that of the matching pipe.

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 120 of: 136
 If the internal diameter of bends is different from that of the matching line pipes the bends
shall be supplied with an internal bevel of about 30 – 40 mm length to adjust the internal
diameter at the welding joint.

4.6.5 Manufacture

Bends shall be made by welding of 2 pressed half-shells under observance of API Standard
1104. The bends shall be manufactured according to a proven method which has to be
approved by the Owner/Engineer.

The joint efficiency factor of all welding seams shall be 1.0. Welding ends and bevels shall be
in accordance with MSS SP-75.

The bends shall be subjected to heat treatment after the forming process. Details on heat
treatment procedure shall be submitted to the Owner/Engineer for approval.

The following documents shall be submitted to the Owner/Engineer for approval prior to
commencement of production:

a) Drawings

The drawings must contain a minimum of the following information:

 material (chemical composition, mechanical properties)

 maximum allowable working pressure

 maximum test pressure

 wall thickness with tolerances

 dimensions:

 internal diameter, length, radius etc. including tolerances

 design of welding seams

 design of welding ends with specification of machining and tolerances

 details on heat treatment

b) Calculation of wall thickness

c) Report on manufacturing procedure qualification tests

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 121 of: 136
 4.6.6 Manufacturing Procedure Qualification Tests

4.6.6.1 General

Prior to commencing production one test bend for each combination of material grade,
diameter, wall thickness and steel charge shall be produced and tested/inspected. The test
bend shall have an angle equal to the maximum angle to be manufactured for the relevant
material grade/wall thickness/diameter. The results have to be submitted to the
Owner/Engineer for approval.

The test bends shall undergo the same manufacturing process as the production bends.

4.6.6.2 Tests

Material properties such as tensile strength and yield strength of the base metal and weld
metal shall be tested after forming of the bends.

The tests are to be carried out in the final heat treated condition of the bend.

The acceptance criteria for mechanical tests including impact testing shall be as per
Specification.

Tests are required for:

 Tensile longitudinal

 Tensile transverse

 Hardness

 Impact (Charpy V-Notch)

The complete test bend shall be non-destructively tested as required by Section (4.6.7) prior
to mechanical testing.

Hardness tests shall be taken on base metal samples from the intrados and the extrados of
the bend body after welding and heat treatment. Hardness measurements on weld seams
shall be as per Figure 1 attached to this document.

Hardness indentations shall be made at the locations indicated in Figure 1. No individual

hardness value shall exceed 248 HV10.

4.6.7 Inspection and Non-Destructive Testing

4.6.7.1 General

Contractor shall allow Owner or its representatives free access to the Works for inspection at
all stages during procedure qualification and the manufacture of the factory bends.

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 122 of: 136
 Inspectors, operators and equipment shall be approved by Owner/Engineer prior to
production. Such personnel shall be fully qualified in accordance with ASNT level II or
Owner/Engineer approved equivalent.

Contractor shall establish, before commencing production, an identification system such that
each bend can be identified against the Mill Certificates and Inspection Reports.

All bends shall comply with the non-destructive testing and dimensional requirements of this
section.

4.6.7.2 Visual Examination

All bends shall be visually inspected internally and externally to ensure that there are no
surface defects and to check dimensional tolerances. Contractor shall submit an internal
examination procedure to Owner/Engineer for approval.

4.6.7.3 Dimensional Tolerances

The wall thickness tolerance at the bevelled ends shall meet the requirements of this
Specification. The wall thickness at other points in the body of the bend shall be measured
ultrasonically at 15 degree intervals round the inner and outer radii of the bend, and shall not
be less than the calculated minimum thickness. The diameter tolerance at the bevelled ends
shall meet the requirements of the Specification.

Out of roundness (ovality) tolerance at bevelled ends shall be 1% and 2.5% on body. The
internal diameter shall be inspected with a rod gauge or calliper capable of checking the
actual ID at any point. Checks shall be made at a minimum of three (3) locations equally
spaced around the circumference of the pipe ID at each end, i.e. at 0°, 120° and 240°.

End squareness to the axis at the bevelled ends shall meet the requirements of API 5L.

All bends shall be tested for ovality with a gauging pig having two sizing plates separated by a
rigid bar of a length twice the pipe ID, with a diameter equal to 95% of the minimum inside
diameter permitted by the Specification.

The plates shall have 16 radial cuts 50 mm long to allow bending of the plates if deformities
are encountered. The sizing plates shall be fabricated from aluminium or other material which
will avoid gouging or scratching of the inside surface of the bends, copper or copper based
alloys shall not be used. The design of the gauge pig shall be approved by Owner/Engineer
prior to the commencement of inspection.

In addition to the above the following tolerances shall apply:

Tolerance on radius of ±1%

curvature:

Planarity: off-plane tolerance: 10 mm max.

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 123 of: 136
 Bend angle: ±1°

Bend buckling is not permitted and shall be cause for rejection of any bend.

4.6.7.4 Non-Destructive Testing

All accessible surfaces of the finished bends shall be examined by magnetic particle
inspection. Any seam welds shall be 100% examined by ultrasonic examination.

All non-destructive examination methods and defect acceptance limits shall conform to the
requirements of Specification and API 5L.

The weld seam shall be subject to radiographic examination for a distance of 200 mm (8”)
from the bevelled end.

Bend ends shall be checked for residual magnetism by means of a portable Gauss-meter.
Residual magnetism shall not exceed 25 Gauss.

All NDE procedures shall be reviewed and approved by Owner/Engineer.

Contractor shall submit details of his NDE procedures for Owner/Engineer’s approval.

4.6.8 Repairs

4.6.8.1 Procedures and Reporting

Repair procedures shall meet the requirements of the Specification. The reports of all repairs
and confirmation of defect removal or rejection shall be submitted to and approved by
Owner/Engineer.

4.6.8.2 Welding

Repairs of base material by welding are not permitted. Repairs of the weld seam maybe
acceptable, provided that defect removal and repair are executed before the final heat
treatment of the bend.

4.6.9 Hydrostatic Pressure Tests

A hydrostatic pressure test in accordance with the requirements of Specification for Carbon
Steel Pipes shall be made on at least 10% of bends but at least on one bend per each
combination of size/wall thickness/material grade. All dimensions shall be checked before and
after the test. The pressure test procedure and equipment used shall be approved by
Owner/Engineer. No permanent deformation shall result from the hydrostatic pressure test.

4.6.10 Marking

The following information shall be applied with synthetic resin paint using a stencil:

 Manufacturer

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 124 of: 136
  Bend number

 Nominal wall thickness

 Wall thickness and steel grades of the joining pipe

 Angle of bend

The following information shall be stamped on the outside of each bend and on both ends:

 Manufacturer

 Bend number

 Steel grade

FIGURE 1

REMOVAL OF CHARPY SPECIMENS AND HARDNESS MEASUREMENT

LOCATIONS

a) Charpy Specimens

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 125 of: 136
 b) Hardness Measurement Locations

 Hardness Surveys (1) and (2) Weld Metal (WM) - Heat

 Affected Zone (HAZ) - Base Metal (BM)

Along straight line from the fusion line towards the BM (with enough indentations to reach
constant values) and towards the WM.

 Hardness Survey (3) (WM)

Minimum of 3 indentations located at centre line of Weld Metal and across each line (1) and

(2) as shown on Figure 1b

 Hardness Survey (4) (HAZ)

Minimum of 3 indentations along straight line parallel to the fusion line which passes the
maximum hardness measurements found during the previous two surveys (1) and (2).

 Distance Between Indentations

 2.0 mm in WM

 1.0 mm in HAZ

 2.0 mm in BM

Note: If the above hardness survey is not practicable, the Contractor shall submit his
proposed procedure to Owner/Engineer for review and approval.

client: TRANSCO
project: WATER TRANSMISSION SCHEME FROM MADINAT ZAYED TO LIWA AND QUSAHWIRA
TENDER NO. N-12192.1
title: SECTION 4C.4
PROJECT PARTICULAR SPECIFICATIONS FOR PIPELINE WORKS

office: Abu Dhabi project: 10632-01 document: 1981001 rev: C sheet: 126 of: 136