⑧

JetA 斗 Pipeline from Pitolganj to Kurmitola Aviation Depot (KAD) includig

Pumpping facilities

MANUFACTURE PROCEDURE SPECIFICATION

FOR INDUCTION BENDS

DOCUMENT NO. P158 一 CPJ-PR-SMP-0017

TECHNICAL SPECIFICATION
Incorporate the comments and
resubmit for final approval.

ASME 816.49
SPECIFICATION
Customer Specification P158-150-PL-SPC-0008-00

PIPE SIZE I 219. 俨 8.18mm

GRADE API 5L X52 PSL2

Company name Date

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1.0 BENDS MANUFACURING PROCESS FLOW CHART

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Stor 咿十一 I Packing

2.0 BENDS MANUFACURING PROCESS SPECIFICATION

1. Product Size:

219.1x7.04mm ，R=10D Bends (R=2191 mm) Angle 90 。

219.1x7.04mm ，R=10D Bends (R=2191 mm) Angle 27 。

219.1x7.04mm ，R=10D Bends (R=2191 mm) Angle 66 。

219.1x7.04mm ，R=10D Bends (R=2191 mm) Angle 30 。

219.1x7.04mm ，R=10D Bends (R=2191 mm) Angle 72 。

219.1x7.04mm ，R=10D Bends (R=2191 mm) Angle 27"

219.1x7.04mm ，R=10D Bends (R=2191 mm) Angle 33 。

Angle 39 0
219.1x7.04mm ，R=10D Bends (R=2191 mm)

2. Specification:

ASME B16.49

Customer Specification P158-150-PL-SPC-0008-00

3. Raw Materials

Material size:φ219.1 咆 .18mm

Grade: API 5L PSL2 X52 SML

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4. Raw Materials Reviewed

4.1 Chemical Composition: meet the requirements specified in Table 1.

Table 1 Product analysis ，maximum. wt. %

Elements Grade C Mn P S Si V Cr Mo

X52 0.13 1.21 0.015 0.009 0.28 0.003 0.08 0.07

Product
Analysis

Elements Grade Ni Nb Ti Cu B Pcm Ceq

X52 0.02 0.02 0.02 0.01 0.001 0.21 0.37

Product
Analysis

Notes: (1) (Nb+V+Ti)%maximum: 0.15%.;

(2) (Ni+Cu+Mo+Cr)%maximum: 0.6%.:

(3) Formula for calculate carbon equivalent :

Pcm=C+ 主 +Mn+~~I+(''' +'60'M+Mo+;: +5B Ceq=C+ 旦旦 +C 川，to+V+Cu 1 叫

30' 20 15 ' 10 6 ~ lR

A full chemical analysis shall be made on base metal per each heat. As a minimum ，all the elements
as per the composition requirement of the applicable consumable specification shall be analysed. The
Nickel and Molybdenum contents shall also be reported.

4.2 Mechanical Properties: meet the requirements specified in Table 2.

Table 2 Mechanical Properties Requirements

CHARPY-V IMPACTTEST

Full size specimens

10x10mm
TENSILE TEST (strip or round bar specimen)

(ASTM E 23)

-20.C
GradeAPI5L
Minimum
Minimum
single
YSπlin. TS Min. YS!TS average for 3
EI%min. value
(MPa) (MPa) (max) speclmens
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。oules，KVη

X52 385 510 0.75 22 82 65

Mechanical Properties shall be done per each lot (Note: A lot means no more than 50 pipes with the
same size which are from the same heat of steel and produced by the same process).

4.3 Hardness test

Hardness test shall be done per each 101.The maximum hardness value of body ，weld seam and HAZ
of mother pipe shall be 235 HB

4.4 Dimensional check

Each mother pipe shall be dimensional checked. The items including diameter ，length ，wall thickness
and straightness shall be checked. The acceptance criteria shall be in accordance with API SPEC 5L.

4.5 Ultrasonic Check

Mother pipe shall be checked 100% for laminar imperfections by UT including along the longitudinal
weld. The acceptance criteria shall be in accordance with API SPEC 5L.
Add Manufacture and Testing of Test Bend
5. Bend Manufacture
Production can be started after completion of all test on the test
5.1 Bending bend and if the test bend meets and fulfill the requirements as per
specification P158-150-PL-SPC-0008-00
5.1.1 Radius of curvature ，angle ，length of tangential ends shall be in accordance with customer standard

P158-150-PL-SPC-0008-00.

5.1.2 The bending operation shall be continuous without interruption during production ，bends with any

interruption during bending will be rejected.

5.1.3 Bending process parameter: meet the requirements specified in Table 3.

5.1.4 AII bends shall be provided with a tangent length at the ends. In case the angle of the bend is less

than or equal to 45 degree ，the tangent length shall be 500 mm and for bend angle greater than 45degree

the tangent length shall be 1000 mm.

5.1.5 Tangent lengths will be not subject to the same induction heating cycle as that of the bent section.
MPS

Cooling water Cooling water

Nominal wall Bending speed temperature pressure
GradeAPI5L Heating temperature (OC)
thickness(mm) rate (mm/min)
CC) (MPa)

X52 8.18 910-930 30~40 20:t15 0.2-0.3

Note: The above data for reference only，the final data should be confirmed by MPQT.

5.2 Initially examines

5.2.1 Surface quality

AII bends shall be visually inspected internally to the maximum possible extent and 100% externally to
ensure freedom from cracks ，gouges ，dents ，grooves ，wrinkles ，bulges ，kinks or surface spalling.
Cosmetic grinding is to be made as necessary to ease visual inspection.

Gouges or grooves which do occur shall be removed by grinding providing that the wall thickness is
not locally reduced below the specified minimum wall thickness.

Deviations from the original contour of the bend shall not exceed 3mm in depth nor shall they exceed
25% of the outside diameter in length. Sharp edged grooves shall be ground out by approved
procedures before applying these criteria.

Minimum wall thickness requirements shall not be compromised. Bends containing deviations as
above shall be rejected. AII kinds of cracks are not acceptable.

5.2.2 Out-of-roundness ，bent angles and wall thickness tests shall be performed on each bend. The
acceptance criteria shall be in accordance with "P158-150-PL-SPC-0008-00 ".

5.2.3 Testing result will be recorded.

5.3 Bevel Preparation

The bends shall be supplied with both ends bevelled to the profile described here below. The root face
shall be 1.6 mm :!: 0.5 mm. Bevelling and taper (if any) shall be carried out by straight machining only.

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5.4 Post bending heat treatment

5.4.1 Tempering shall be adopted.

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5.4.2 Tempering parameter: meet the requirements specified in Table 4.

Table 4 Tempering parameter

Holding Heating speed

Holding time Cooling
Nominal wall temperature rate
GradeAPI5L
thickness(mm) Cmin) method
CC) CC/h)

X52 7.04 500士 10 三 200 35 Air cooling

5.4.3 Heating cycle of heat treatment shall be continuously recorded on a printed chart.

6. Dimensional Inspection

Dimensional inspection ，including thickness measurements ，shall be made on each bend after final heat

treatment and bevel preparation. A report shall be issued for each bend. Dimensional inspection shall be
in accordance with ASME B 16.49 and P158-150-PL-SPC-0008-00 Specification

6.1 Wall thickness

Wall thickness measurements shall be taken using a suitably approved ultrasonic procedure.

The tolerance for the wall thickness shall be -12.5 ，+ 15% on the specified nominal wall thickness.

6.2 Out-of-roundness

At any point throughout the body of bend ，the difference between the maximum and minimum Outside
Diameters shall not exceed 2.5% of the agreed nominal Outside Diameter.

100 mm range away from ends ，the Out-of-roundness not exceed 1%.

Dr'lln

6.3 Radius of curvature

6.4 Bend angle

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(i.e. bend angle is not the included angle). Bend angle shall be accurate to within 0.5 of the nominal
0
:t

bend angle.

6.50 仔-plane
0
The maximum off-plane shall be :t 1 •

/ / /' ./

6.6 Squareness

Ends of bend shall be machined perpendicular to the longitudinal axis of the bend. Only a slight
reaming of pipe ends may be permi 忧ed with prior approval of the Inspector. End squareness shall be
maximum 2 mm.

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6.8 Straight tangent

Tangent length shall be 500mm or 1000mm. Use of welded pup pieces as tangent lengths is not
allowed.

6.9 Pig gauge trial

A pig gauge shall be passed freely through fulllength of each bend. The gauge shall have two
equispaced and parallel 6 mm thick circular plates ，each at least 95% of the connected pipeline
nominallD ，separated bya rigid bar of totallength 1x Nominal OD. If the gauging plates are damaged
during the test ，the test shall be considered failed and the bend rejected.
Destructive test has to be carried out for the Test
7. Visual and Non-destructive Inspection
bend as per Specification P158-150-PL-SPC-0008-00
Visual and non-destructive inspection shall be made on each bend after final heat treatment and bevel
preparation.

AII NDT personnel shall be qualified and certified in accordance with ISO 9712 ，ASNT SNT-TC-1A or
equivalent to the appropriate level of competence.

7.1 Visual inspection for laminations ，cracks ，notches ，gouges and other imperfections shall be performed
on the complete outer and ，if practical ，the inner surface of the bend.

7.2 For all bends ，the bend body shall be inspected over an arc of each side of the extrados by MT in
accordance with ASTM E709.

AII cracks ，laps ，laminations and all rounded indications greater than 3 mm (0.118 in) in any direction
shall be classed as defects and shall be repaired.

7.3 AII bend ends shall be ultrasonically examined over 100% of the area within 100 mm of the bend end
to check for laminations. Inspection procedure shall be as per ASTM A578 Std.

Laminar imperfection shall not exceed 6.4 mm in the circumferential direction or have an area in
excess of 100 mm2•

7.4 AII bends shall be 100% externally inspected by wet Magnetic Particle Inspection over a longitudinal
band covering 90 within the extrados plus any ground area. The inspection procedure shall be in
0

accordance with ASME Section V，Article 7 ，using the yoke method

Acceptance levels shall be in accordance with ASME Section V 川 1，Division 1.

7.5 The NDT shall be pe 斤。rmed after heat treatment.

如1PS

No residual magnetism in either longitudinal or transverse direction to the pipe axis shall be greater than

20 Gauss. Demagnetization shall be applied if the magnetic measurement is greater than the acceptable

Iimit i.e. 20 Gauss.

8. Repair of Defects

Any repair shall eomply with the requirements of ASME B16.49 AND P158-150-PL-SPC-0008-00
Specification

8.1 Repair by welding of bends is not permi 忧ed.

8.2 Defects ineluding laps ，shells and slivers

Defects including laps ，shells and slivers may only be removed by grinding provided that the minimum
specified wall thickness is maintained. Any grinding shall leave a smooth surface profile.

8.3 The location of repair work

The locations of any repair work shall be recorded so that independent checks can be made at a later
date.

8.4 A local Magnetic Partiele Inspeetion

A local Magnetie Particle Inspection shall be carried out to verify that the defect has been completely
removed and that the repair is aeceptable. Wall thickness checks shall be made on the ground areas
with ultrasonie inspection to confirm that the specified minimum wall thickness is maintained. The
above does not apply to cosmetic grinding.

8.5 The method of degaussing

Direct current degaussing method: through the application of magnetometer ，the direction ，size and other
parameters of the residual magnetic field of the steel pipe can be determined. Configure the welding wire
with the section of 35-50mm2 into the steel pipe and connect the wire with the welding AC in sequence to
ensure the direction of magnetic field action is opposite to that of the steel pipe. In the initial degaussing
process ，the current is about 80-110A; In the process of degaussing ，the magnetometer should be used
periodically to measure the degaussing status when the power is switehed on. If necessary ，the current
should be controlled ，or the direction of current should be changed. After the whole degaussing process ，
in order to realize the slow reduction of magnetic f1ux，the current value should be gradually redueed
within 1-3 min until it reaehes o. Finally ，cut off the power supply.

9.
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10. Marking of Bends ， Handing ，Transport and 5torage

As a minimum for each bend the following markings are stenciled at both ends internally with indelible
paint.

一 manufacturer's name or trade mark;

--diameter ，outside or inside;

--minimum wall thickness;

--bend angle;

一 bend radius;

--purchase order and item number;

--Pipe No.
--heat number or manufacturer's heat identification;

一 API-5L material grade;

一 Measured weight;

--any additional marking specified in the purchase order.

Allloose and foreign material i.e. rust ，grease etc. shall be removed from inside and outside of the
bend.

A coat of antirust paint shall be applied on the bends for protection during transit and storage.

80th ends of the bends shall be suitably protected to avoid any damage during transit by means of
metallic or high impact plastic bevel protectors.

Package shall be marked legibly with indelible marking ink to indicate the following:

a) Order Number;

b) Package Number;

c) Manufacturer' s Name;

d) Size (Inches) and wall thickness (mm);

e) Radius of bend (mm) and bend angle.

11.DOCUMENTATION
MPS

Documentation relating to the supply of goods shall be provided by the Vendor/Sub-Vendor. AII
documents shall be reviewed by Vendor/Sub-Vendor's Quality team and approved by the Employer.

Full certification of the procedure and results of bending ，inspection and testing shall be provided by
the Vendor/Sub-Vendor and certified by Employer .

Certificates shall be provided by Vendor/Sub-Vendor in accordance with applicable codes and

standards and shall be approved by Employer

Certification shall cover all results required by this specification. AII certificates shall be marked with
su仔 icient information to enable full traceability to the items it represents and the relevant specifications
and procedures.

The external coating for hot bend pipeline shall use double fusion bond epoxy (FBE) ，the total
thickness should be at least 800μm ，the details requirements refer to P158-150-PL-SPC-0014- 00
speci 白cation for fusion-bonded epoxy coating for horizontal directional drilling and hot bend

The Internal coating shall be as

per Shell recommendation and
follow code EI 1541