Santos Facilities Engineering Standard

Specification 1515-50-S003 Rev 1

Page 1 of 5

Santos Specification
Title: Specification for Hot Bends

Table of Contents:
FOREWORD......................................................................................................................... 2
1.0

SCOPE ...................................................................................................................... 3

2.0

STANDARDS, CODES OF PRACTICE, REFERENCES ........................................... 3

3.0

TECHNICAL CONSIDERATIONS ............................................................................. 3

3.1
3.2
3.3
3.4
3.5
3.6
3.7

Materials ........................................................................................................... 3
Mechanical Requirements................................................................................. 3
Quality Assurance............................................................................................. 4
Inspection and Testing...................................................................................... 4
Additional Requirements for Duplex Stainless Steels........................................ 4
Post Bend Operations....................................................................................... 4
Preparation for Shipment .................................................................................. 5

4.0

REVISION NOTES .................................................................................................... 5

5.0

APPENDICES............................................................................................................ 5

Custodian

R J Schulz, Principal Engineer Mechanical

Issued by

D A Craig, Manager Facilities Engineering Governance

Date

January 2006

Rev Date: 12 Jan 06

Issued by Facilities Engineering Governance Department

Printed document may not be current issue. Check TIMS

Santos Ltd 2006

ABN 80 007 550 923

Santos Facilities Engineering Standard

Specification 1515-50-S003 Rev 1
Page 2 of 5

FOREWORD
Application of this Facilities Engineering Standard shall meet requirements of Santos
Environment Health and Safety Management System in particular, but not limited
to:
EHSMS 02 Legal and Other Obligations
EHSMS 06 Training and Competency
EHSMS 09 Hazard Identification, Risk Assessment and Control
EHSMS 10 Contractor and Supplier Management
EHSMS 11 Santos Operations
EHSMS 12 Management of Change
EHSMS Glossary
HSHS 06 Electrical Safety
Facilities Engineering Standards apply to all Santos onshore facilities and are based
on Australian Regulations and Standards. When applied outside of Australia, local
Regulations, Codes of Practice and environmental conditions shall take precedence.
Compliance with Regulations and Engineering Standards is compulsory in
accordance with EHSMS 02. The current Facilities Engineering Standards shall
apply unless specifically stated within individual standards or when directed by
Santos Principal Engineers. Regulations may superimpose retroactive provisions.
Use of this Facilities Engineering Standard is MANDATORY. If any part of this
Standard appears inadequate, unsuitable or not cost effective, consult with the
Custodian to agree a suitable solution. This may result in a revision to the Standard.

Rev Date: 12 Jan 06

Issued by Facilities Engineering Governance Department

Printed document may not be current issue. Check TIMS

Santos Ltd 2006

ABN 80 007 550 923

Santos Facilities Engineering Standard

Specification 1515-50-S003 Rev 1
Page 3 of 5

1.0

SCOPE
This specification defines minimum requirements for manufacture, inspection and
testing of long radius pipe bends for use in liquid and gas transmission systems.

2.0

STANDARDS, CODES OF PRACTICE, REFERENCES

Pipe bends shall meet requirements of the latest edition of AS 2885 Pipelines - Gas
and Liquid Petroleum.

3.0

TECHNICAL CONSIDERATIONS

3.1

Materials
The material used for manufacture of bends shall be as specified in the purchase
order. Any variation in material grades or thickness or bend radius shall be approved
prior to manufacture.

3.2

Mechanical Requirements
Each bend shall be formed from one piece with no circumferential weld within the
length of bend. Induction bending is preferred.
Minimum bend radius is 5 x pipe nominal diameter. The effect of heat on pipe
metallurgical properties and pipe wall thinning due to bending shall be evaluated.
Note: Thinning of up to 20% may occur on 5D bends. This may require use of thicker
pipe or increased bend radius to compensate for thinning.
Longitudinal welds in ERW and submerged arc welded pipe shall be located within a
5 band either side of the neutral axis.
Each bend end shall be bevelled 30 for butt welding with a nominal root face of
1.6 mm 0.8mm.
Tolerances shown are maximum acceptable deviations:
Radius

1%

Bend angle

1.5 degrees

Ovality

1.5%

Wall thickness of
finished bend

- 10.0% of pipe WT, or Santos Engineer to

nominate required thickness of formed bend

Rev Date: 12 Jan 06

Issued by Facilities Engineering Governance Department

Printed document may not be current issue. Check TIMS

Santos Ltd 2006

ABN 80 007 550 923

Santos Facilities Engineering Standard

Specification 1515-50-S003 Rev 1
Page 4 of 5

3.3

Quality Assurance
A qualification bend shall be manufactured for each pipe size and material grade
specified. This qualification bend shall be subjected to corrosion resistance testing,
metallurgical evaluation and mechanical testing as required by Santos.
A full report on the qualification bend shall be produced prior to the commencement
of production bending. The report shall contain a record of all bending control
parameters including cooling rate control parameters. It shall include complete
details of all inspection and testing and shall be available to Santos representatives
on request.
The Manufacturer shall retain all records in a quality system consistent with
ISO 9001.

3.4

Inspection and Testing

Santos or its nominated representative shall have the right to witness execution of
any tests required by this specification.
Testing to confirm ovality shall be by callipers in two directions in at least four
positions equally spaced in the bend body.
Wall thickness at the bend extrados shall be checked in at least four equally spaced
positions by ultrasonics and compared to parent material so that thinning tolerance is
not exceeded.
Visual inspection shall confirm there is no buckling in the bend area.

3.5

Additional Requirements for Duplex Stainless Steels

Bends manufactured from duplex stainless steel shall be given additional testing as
follows, and as detailed in Appendix 1:
100% external dye penetrant examination of all bends and bevelled ends,
according to AS 2062.
Hardness testing of the induction-heated zone at the bend mid point and heat
affected zones at the start and finish points of one bend per pipe length.
Hardness results shall comply with requirements of ASTM A790.

3.6

Post Bend Operations

Post bend heat treatment shall be noted in purchase order if required.
Carbon steel bends shall be supplied without surface treatment unless otherwise
specified.
Duplex stainless steel bends shall be grit-blasted internally and pickled and
passivated so that corrosion protection during service is not impaired.

Rev Date: 12 Jan 06

Issued by Facilities Engineering Governance Department

Printed document may not be current issue. Check TIMS

Santos Ltd 2006

ABN 80 007 550 923

Santos Facilities Engineering Standard

Specification 1515-50-S003 Rev 1
Page 5 of 5

Bends shall be clearly marked with the following information by paint stencilling on
outside of pipe:
Manufacturer's name
Material
Outside diameter at bevel end
Wall thickness at bevel end
Angle of bend
Santos purchase order number
3.7

Preparation for Shipment

Machine bevelled ends shall be protected by a rust preventative and fitted with a
suitable cap taped to the pipe in such a manner to prevent damage during transport.

4.0

REVISION NOTES
Revision 1
Mechanical requirements for pipe thinning revised section 3.1, 3.2.
Wall thickness under tolerance now -10% (was -12.5%).
Reaffirmed
Prepared

Russell Schulz, Principal Mechanical Engineer

Oct 2005

Reviewed

Harry Moss, Principal Integrity Engineer

Dec 2005

Approved

David Craig, Manager Facilities Engineering Governance

Jan 2006

Revision 0
Formerly SABU Specification 1500-50-S003 Rev 2

5.0

Prepared

R J Schulz, Principal Mechanical Engineer

Aug 2001

Reviewed

C J Moss, Senior Metallurgist

Sept 2001

Approved
Issued

D P Young, P A Strimaitis, Engineering Managers

D R Poole, Corporate Engineering

Oct 2001
Oct 2001

APPENDICES
Appendix 1

Rev Date: 12 Jan 06

Testing requirements for qualification procedure

duplex stainless steel only

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Santos Ltd 2006

ABN 80 007 550 923

Santos Facilities Engineering Standard

Specification 1515-50-S003 Appendix 1 Rev 1
Page 1 of 1

Appendix 1
TESTING REQUIREMENTS FOR QUALIFICATION PROCEDURE
DUPLEX STAINLESS STEEL ONLY

Comments

Position of Sample

Dye
Penetrant

External

Tensile
Test

Conducted at ambient
temp

Hardness

Can use
microstructure sample

Parent
Pipe Microstructure

Comparison of
Aust/Ferrite ratio &
consistency through Xsection, plus
intermetallics

Bend - from extrados

Charpy

Ave of 3 tests per

region, test temp 0oC

Bend - from
extrados, both
samples longitudinal
orientation

Rev Date: 12 Jan 06

Bend - from
extrados, both
samples longitudinal
orientation

Issued by Facilities Engineering Governance Department

Printed document may not be current issue. Check TIMS

Transition
Zone

Bend

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Santos Ltd 2006

ABN 80 007 550 923