KUWAIT OIL COMPANY (K.S.C.

STANDARDS PUBLICATION

KOC MATERIAL SPECIFICATION

FOR

INDUCTION BENDS

DOC. NO. KOC-MS-002

STANDARDS TEAM
DOC. NO. KOC-MS-002 Page 1 of 29 REV. 1

STANDARDS PUBLICATION

KOC M ATERIAL SPECIFICATION

FOR

INDUCTION BENDS

DOC.NO. KOC-M S-002

STANDARDS TEAM
I DOC. NO. KOC-MS-002 Page 2 of 29 REV. 1

KOC MATERIAL SPECIFICATION

FOR

INDUCTION BENDS

(This Material Specification supersedes KOC Group

Engineering Specification No.015-IH-1011)

ISSUING AUTHORITY:

STANDARDS TEAM
 DOC. NO. KOC-MS-002 Page 3 of 29 REV. 1

TABLE OF CONTENTS

Page No.

FOREWORD 5

1.0 SCOPE 6

2.0 APPLICATION 6

3.0 TERM INOLOGY 6

3.1 Definitions 6
3.2 Abbreviations 8

4.0 REFERENCE STANDARDS, CODES AND SPECIFCICATIONS 9

4.1 International / National Standards and Codes 9
4.2 KOC Standards and Specifications 10
4.3 Order of Precedence 11

5.0 M OTHER PIPE M ATERIALS 11

6.0 M ANUFACTURING 12

7.0 POST-BENDING HEAT TREATM ENT 13

8.0 QUALIFICATION OF BEND M ANUFACTURING PROCEDURE 14

9.0 PRODUCTION BENDING 14

10.0 INSPECTION AND TESTING 14

10.1 General Requirements 14
10.2 Qualification Test Bend 15
10.3 Testing and Inspection Frequency 15
10.4 Production Bends 15
10.5 Destructive Test s for Qualification Test Bend 16
10.6 Sour Service Testing 17

11.0 DIM ENSIONAL INSPECTION 18

11.1 General 18
11.2 Wall Thickness 18
11.3 Out-of-Roundness (Ovality) 19
11.4 Outside Diameter 19
11.5 Inside Diameter 19
11.6 Bend Radius 19
11.7 Bend Angle 19
11.8 Off-Plane 19
11.9 Centre-to-End Dimensions 19
 DOC. NO. KOC-MS-002 Page 4 of 29 REV. 1

11.10 Bend End Preparation 19

11.11 End Squareness 20
11.12 Pig Gauge Trial 20
11.13 Surface Conditions, Imperfections and Def ects 20

12.0 NON-DESTRUCTIVE TESTING 20

12.1 General 20
12.2 Visual Inspection 20
12.3 Magnetic Particle Testing 21

13.0 M ARKING OF BENDS 21

14.0 HANDLING, TRANSPORT AND STORAGE 22

15.0 BEVEL PROTECTION 22

16.0 PACKING 22

17.0 QUALITY ASSURANCE 22

18.0 DOCUM ENTATION AND CERTIFICATION 23

18.1 Documents Required Before Starting Production 23

18.2 Manufacturing Record Book (MRB) Documents 23

APPENDIX 1 : BEND DATA SHEET 25

APPENDIX 2 : “FIGURES” 27

ACKNOWLEDGEM ENT 28
 DOC. NO. KOC-MS-002 Page 5 of 29 REV. 1

FOREWORD

This document “KOC M aterial Specification for Induction Bends (KOC-M S-002)” is
intended t o provide an added component for the pipelines elements that form the
cross country pipelines for transportation of hydrocarbons and other fluids.

This Material Specification (M S) has been approved by Standards Team in

consultation w ith Standards Technical Committee (STC) for consistent use by KOC
User Teams throughout corporate engineering and operational functions of Kuw ait
OIL Company (K.S.C). This Material Specification w ill supersede KOC Group
Engineering Specification No. 015-IH-1011.

Feed back as w ell as any comments or suggestions derived f rom the application of
this specification at any stage of design, purchase, mill execution or field construction
are encouraged and should be directed to:

The Team Leader Standards Team

(Chairman Standards Technical Committee)
Industrial Services Group, KOC
P.O. Box - 9758, Ahmadi 61008
State of Kuw ait

Task Force Responsible for this M aterial Specification (M S)

The preparation of this Material Specification has been entrusted by the

Standards Technical Committee (STC) to the Task Force No. (TF-MS/002)
comprising of the follow ing members:

Mr. Mohd. Emam Insp. & Corr. Team (S&E) TF Leader Tel. No. 65254
Mr. Sayed Abul-Khair Insp. & Corr. Team (S&E) Author/Member Tel. No. 61455
Mr. Tareq Al-Masoud Insp. & Corr. Team (N&W) Member Tel. No. 61776
Mr. N. Ramanathan Major Projects Team-IV Member Tel. No. 66960
Mr. A. K. Ghosh Design Team Member Tel. No. 61768
Mr. Richard Eltringham PMC (Fluor) Member Tel. No. 61301
 DOC. NO. KOC-MS-002 Page 6 of 29 REV. 1

1.0 SCOPE

1.1 This Material Specification (M S) covers the design, material, manufacturing,

testing, inspection and marking requirements for induction bends made from
seamless (SMLS) or longitudinal submerged arc w elded (SAWL) carbon steel
line pipe. Bends shall be suitable for sour or non-sour services. Helical (spiral)
w elded pipes shall not be acceptable for manufacturing of induction bends.

1.2 Induction bends manufactured to this Specification are intended for

transportation and distribution piping systems designed and constructed to
ASME B31.4 and ASME B31.8 codes. This Specification is based on ASME
B16.49 (2007). The requirements stipulated herein are additions or
modifications to ASME B16.49 standard.

2.0 APPLICATION

2.1 The design, material, manufacturing, testing, inspection and marking

requirements for induction bends shall conform to the requirements of this
KOC Material Specification and the reference standards / codes mentioned
herein.

2.2 Any exceptions or deviations from this Material Specification, along w ith their
merits and justifications, shall be brought to the attention of KOC Controlling
Team for their review , consideration and amendment by Standards Team (if
required).

2.3 Compliance w ith this KOC Material Specification does not itself confer
immunity from legal or contractual obligations.

3.0 TERM INOLOGY

3.1 Definitions

For the purposes of t his Specification, the follow ing definitions shall apply.

3.1.1 Accreditation

Third party attestation related to a conformity assessment body conveying

formal demonstration of its competence to carry out specific conformity
assessment tasks

3.1.2 Accreditation body

Authoritative body t hat performs accreditation

3.1.3 Bend angle

Amount of directional change through t he bend

 DOC. NO. KOC-MS-002 Page 7 of 29 REV. 1

3.1.4 Bend radius

Distance from the centre of curvature to t he centerline of t he bent pipe

3.1.5 Extrados

The outside arc of t he bend

3.1.6 Hot induction bending

Continuous bending process w hich utilizes induction heating to create a

narrow , circumferential, heated band around the material being bent

3.1.7 Intrados

The inside arc of the bend

3.1.8 Inspection

Examination of the product, process and determination of its conformity w ith

specific requirements

3.1.9 Manufacturing procedure specification

Document w hich specifies the properties and description of the mother pipe,
the bending procedure, the post -bending heat treatment equipment and cycle,
the qualification bend testing results, the non-destructive testing procedures
and the w eld end bevel details used for the manufacture of the bends

3.1.10 Minimum (design) w all thickness

The w all thickness specified or computed in accordance w ith the piping code
as the minimum acceptable for the temperature and pressure application

3.1.11 Mother Pipe

Straight section of pipe from w hich an induction bend is made

3.1.12 Nominal (design) w all thickness

The w all thickness specified on the order or marked on the bend

3.1.13 Nominal pipe size (NPS)

Numerical inches designation of size w hich is common to components in

piping systems of any one size
 DOC. NO. KOC-MS-002 Page 8 of 29 REV. 1

3.1.14 Ovality, % (out of roundness)

[(O.D. max. – O.D. min.) / O.D. nom] x 100, w here O.D is a liner
measurement of the maximum, minimum, or nominal outside diameter

3.1.15 Procedure

Specified w ay to carry out an activity or a process

3.1.16 Qualification test bend

A bend segment that is produced and tested and is used to qualify the
bending procedure

3.1.17 Specification

Documents stating requirements

3.1.18 Tangent

Straight section at the ends of an induction bend

3.1.19 Testing

Determination of one or more characteristics of an object of conformity

assessment, according to a procedure

3.1.20 Transition zone

Areas at the start and stop points of bending w hich include material that
extends from the unheated mother pipe to the material that has been heated
to the full bending temperature

3.2 Abbreviations

CE Carbon Equivalent
CLR Crack Lengt h Rat io
CTR Crack Thickness Rat io
CSR Crack Sensit ivit y Rat io (Know n also as Crack surface rat io)
CVN Charpy V-Notch
HB Brinell Hardness
HIC Hydrogen-Induced Cracking
HV Vickers Hardness
KOC Kuw ait Oil Company
MRB Manufacturing Record Book
MT Magnetic Particle Testing/Examination
NDT Non-Destructive Testing (synonymous t o NDE, Non-Destructive
Examination)
 DOC. NO. KOC-MS-002 Page 9 of 29 REV. 1

PO Purchase Order
PSL Product Specification Level
RT Radiographic Testing/Examination
SAWL Submerged-Arc Longitudinal Welding process for pipe during manufacture
SMLS Seamless
SSC Sulphide Stress Cracking
TMCP Thermomechanical Controlled Process
UT Ultrasonic Testing / Examination

4.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS

The latest revision of the follow ing standards, codes and specifications shall
apply:

4.1 International / National Standards and Codes

API Q1 Specification for Quality Programs for the

Petroleum, Petrochemical and Natural Gas
Industries
API 5L/ISO 3183 Specification for Line Pipe. Steel pipe for pipeline
transportation systems
ASME B16.25 Butt w elding Ends
ASME B16.49 Factory - Made Wrought Steel, Butt w elding
Induction Bends for Transportation and
Distribution Systems
ASME B31.4 Pipeline Transportation System for Liquid
Hydrocarbons and Other Liquid
ASME B31.8 Gas Transmission and Distribution Piping
Systems
ASME SEC V Nondestructive Examination
ASME SEC VIII Div.1- Rules for construction of pressure vessels
ASTM A370 Standard Methods and Definitions for Mechanical
Testing of Products
ASTM E8 Standard Test Methods for Tension Testing of
Metallic Materials
ASTM E709 Standard Guide for Magnetic Particle Testing
ASTM E 797 Standard Practice for Measuring Thickness by
Manual Ultrasonic Pulse-Echo Contact Method.
 DOC. NO. KOC-MS-002 Page 10 of 29 REV. 1

BS EN 10204 Metallic Products - Type of Inspection

Documents
BS EN ISO 100021-1 Metallic materials Tensile testing - Part 1:
Method of test at ambient temperature
ISO 9000 Quality management systems - Fundamentals
and vocabulary
ISO 9004 Quality management systems - Guidelines for
performance improvement
ISO 10474 Steel and steel products - Inspection documents
ISO 13665 Seamless and Welded Steel Tubes for Pressure
Purposes – Magnetic Particle Inspections of the
Tube Body for the Detection of Surface
Irregularities
ISO 15590-1 Petroleum and Natural Gas Industries - Induction
Bends, Fittings and Flanges for Pipeline
Transportation Systems - Part 1: Induction Bends
ISO / IEC 17025 General requirements for the competence of
testing and calibration laboratories
NACE MR 0175 / Petroleum and natural gas industries – Materials
ISO 15156 for use in H2 S containing environments in oil and

gas production (Parts 1 to 3)

NACE TM 0177 Laboratory Testing of Metals for Resistance to
Sulfide Stress Cracking and Stress Corrosion
Cracking in H2 S Environments
NACE TM 0284 Evaluation of Pipeline and Pressure Vessel Steels
for Resistance to Hydrogen-Induced Cracking
SSPC SP-6 Commercial Blast Cleaning

4.2 KOC Standards and Specifications

KOC-G-004 KOC Standard f or Packing, Marking and

Documentation
KOC-MS-001 KOC Material Specification - Line Pipe Specification
for Sour Service
KOC-Q-014 KOC Standard f or Project QA/QC Requirements
 DOC. NO. KOC-MS-002 Page 11 of 29 REV. 1

4.3 Order of Precedence

In case of conflict s betw een the requirements of this Specification and

the referenced codes, standards, and specifications, the follow ing
precedence shall apply:

a) This Specification KOC-MS-002

b) Project Specifications

c) KOC Standards and Specifications

d) Other International Codes and Standards

5.0 M OTHER PIPE M ATERIALS

5.1 Hot induction bends for sour service shall be manufactured from carbon steel
SMLS or SAWL pipes conforming to t he KOC Material Specification KOC-MS-
001 and NACE MR 0175 / ISO 15156. Induction bends for non-sour service
shall be made from pipes manufactured to KOC-MS-001 w ithout invoking sour
service requirements. Induction bends shall not contain st rip / plate end w elds.

5.2 Mot her pipes manufactured from normalized, quenched and tempered or TMCP
processes are acceptable. To preserve the mechanical propert ies of induction
bends made of TMCP pipes, an increase in Carbon, Manganese, Nitrogen and
the CE are allow ed. Details of such chemical composition shall be agreed w ith
KOC.

5.3 HIC and SSC testing shall be carried out on the finished qualification test bends
(Refer to KOC-MS-001) only for sour service.

5.4 Mother pipes to be used for the manufacture of the bends shall be procured
from the KOC approved line pipe manufacturers. The mill test certificates of
pipes shall be provided for KOC review and approval prior to commencing t he
bending process.

5.5 The w all thickness of the mot her pipe shall be suitable for the induction bending
process in order to achieve the minimum w all thickness requirements after
bending.

5.6 The pipe surfaces shall be free of contamination prior to and during the bending
process and shall conform t o clause 5.1 of ASME B16.49. Grit blasting to a
minimum of SSPC SP-6 shall be applied irrespective of steel grade and strength.
 DOC. NO. KOC-MS-002 Page 12 of 29 REV. 1

6.0 M ANUFACTURING

6.1 Bends shall be manufactured using the high frequency induction heating and
forming method based on a qualified bending procedure.

6.2 The hot induction bending manufacturing procedure shall be submitted for KOC
review and approval before starting the bending qualification tests.

6.3 The manufacturing procedure shall include, but is not limited to the follow ing
details (refer to ISO 15590-1):

a) Mother pipe data (purchasing specifications, diameter, minimum or

nominal w all thickness, length, manufacturer, inspection documents
including chemical composition, mechanical properties, NDT results,
dimensions, w elding procedure, w eld seam repair specification, etc.)

b) Testing and qualification requirements for qualification test bend and

production bends

c) Bending process details including essential variables limits as per

Table 1 of this Specification

d) Quality plan

e) Details of post bending heat treatment including furnace details

f) End protection, coating, marking, etc.

6.4 The bend manufacturing procedure shall be qualified on a test bend prior t o t he
start of production in accordance w ith this Specification. Test bend shall be
subject to the mechanical and non-destructive test requirements of this
Specification.

6.5 Once the bending operation has commenced, no stoppage shall be permitted
until the entire bend has been completed. The manufacturer shall maintain
continuous records of the bending paramet ers for each bend.

6.6 Material grade, bend size, radius, angle, et c shall be specified in the bend data
sheet.

6.7 Unless otherw ise specified in the purchase order, the bending radius shall be of
five times (5D) the nominal outside diameter of the pipe and the maximum
ovality throughout body of the bend shall not exceed 2.5% of the nominal pipe
size used for the pipeline.
 DOC. NO. KOC-MS-002 Page 13 of 29 REV. 1

6.8 Unless otherw ise specified in bend data sheet, all bends shall be provided w it h
straight tangents at the ends. The tangent length shall be 500 mm (20 inch) or
one time pipe size w hichever is greater.

6.9 For bends manufactured from the SAWL line pipe, the longitudinal seam shall
be located in the plane of minimum def ormation (bend neut ral axis) w ith a
tolerance of ± 5° .

6.10 Bends shall not have any girth w eld. No repair by w elding is allow ed on any part
of the bend body. The excess w eld material at the inside of the bend shall be
removed over a distance of 100 mm (4 in) at bot h ends.

Table 1 : Bend M anufacturing Essential Variables

Essential variable Limits of variations

Pipe w all thickness ± ± 3mm ( ± 0.12-inch)
Bend radius to diamet er ratio (R/D) + 1+ 1 R/-0
Weld seam ± 5 degree from the neutral axis
Post - bending heat treatment M Method: no change allow ed
Soaking temperature: ± 15° C(± 59 °F)
Soaking time: + 15 - 0 minutes
Forming velocity ± 2.5 mm (0.1 in) /min
Forming temperature ± ± 25° C (± 77° F)
Coil design ± ± No change allow ed
Induction heating pow er ± ± 5%
Induction heating frequency ± ± 20%
Coolant type No change allow ed
Cooling w ater temperature ± 1± 15° C (± 59° F)
Coolant flow rate/pressure ± ± 10%
Hot/cold forming or sizing after N None
bending

7.0 POST- BENDING HEAT TREATM ENT

7.1 Post-bending heat treatment shall be performed to achieve the required material
properties, improve corrosion resistance, remove transition zones at the ends of
the bend arc or to relieve residual stresses.

7.2 The follow ing heat treatment processes are allow ed subject to KOC approval as
part of t he manufacturing procedure:

a) stress relieving (SR) or tempering

b) normalizing (N)
c) quenching and tempering (QT)
 DOC. NO. KOC-MS-002 Page 14 of 29 REV. 1

7.3 The requirements stipulated in clause 9.0 of ASME B16.49 shall be applied. Post
bend heating for dimensional corrections on production bends is not acceptable.

7.4 Post bend heat treatment details shall include but not limited to the follow ing:

a) temperature and rates of heating and cooling;

b) methods of cont inuous control and recording;
c) furnace details, calibration, t hermocouple calibration, etc.

8.0 QUALIFICATION OF BEND M ANUFACTURING PROCEDURE

8.1 The bend manufacturing procedure shall be qualified on a test bend from each
heat prior to the start of production. Test bend shall be made from the same
pipe material as specified in the bend data sheet.

8.2 The qualification bend shall be inspected and tested in accordance w ith
clause 11.2 of this Specification. Any change in the essential variables
provided in Table 1 of this Specification shall require a requalification.

8.3 Unless otherw ise approved by KOC, the qualification test bend shall be made
to an angle of 90° using the approved manufacturing procedure.

9.0 PRODUCTION BENDING

9.1 The bending parameters applied to the successful qualification bend shall be
recorded and shall be applied for the production bends.

9.2 In case the bending process parameters depart from the qualified
manufacturing procedure, the bend shall be discarded.

9.3 Inspection and testing to be carried out on the test bend and production bends
shall be as per clause 11.0, Table 2 and Table 3 of this Specification.

10.0 INSPECTION AND TESTING

10.1 General Requirements

10.1.1 Testing on bending qualification procedure and product ion bends shall be
made as per Table 2 of this Specification.

10.1.2 All testing and inspection acceptance criteria shall meet KOC-MS-001 “ KOC
Material Specification-Line Pipe for Sour Service” for the same grade and
thickness after post -bending heat treatment process.

10.1.3 Should the test bend fails to comply w ith the requirements of this
Specification, the bend manufacturing procedure shall be considered as
disqualified. The manufacturing procedure shall be revised and re-qualified.
 DOC. NO. KOC-MS-002 Page 15 of 29 REV. 1

10.1.4 The manufacturer shall develop and submit for KOC approval a Quality Control
Plan that includes all inspection and testing requirements in this Specification.

10.1.5 All laboratory testing shall be undertaken, using calibrated and certified
equipments at laboratories that have been accredited and certified in
accordance w ith ISO/IEC 17025 by a certified accreditation body . The
induction bend manufacturer testing laboratory shall be accredited similarly.

10.2 Qualification Test Bend

10.2.1 The testing and inspection requirements for qualification of manufacturing

procedure shall be made as per Table 2 of this Specification given below .

10.2.2 The location and type of tests shall be as per Table 3 of this Specification
given below and fig. 2 (identical to ASME B16.49 fig. 2).

10.3 Testing and Inspection Frequency

One (1) qualification t est bend shall be made per heat, size, grade and w all
thickness.

10.4 Production Bends

Each production bend shall be inspected as per Table 2 below :

Table 2: Summary of Testing and Inspection Requirements for Test Bend (T)
and Production Bends (P)

Type of Type of Acceptance

Remarks
Testing/ inspection bend Criteria
Tensile T API 5L PSL2 Pipe body and longitudinal
ASTM A370 seam w eld
CVN Impact T API 5L PSL2 Pipe body and
ASTM A370 longitudinal seam w eld
Through-thickness T Maximum hardness -
hardness 238 HV10 (226 HB).
Surface hardness T& P Maximum hardness -
238 HV10 (226 HB).
Metallography T Complete penetration -
and Fusion
HIC T KOC-MS-001 Only for sour service.
Appendix B Samples from extrados and
the finish transition zones.
SSC T KOC-MS-001 Only for sour service.
clause 6.4.3 Samples from extrados and
the finish transition zones.
Guided bend (w eld T API 5L -
seam)
Visual inspection T& P API 5L Clause 10.2.7 -
Weld seam (UT/RT) T& P KOC-MS-001 -
Appendix D
Bend ends P KOC-MS-001 All the bend ends
(laminations) Appendix D
 DOC. NO. KOC-MS-002 Page 16 of 29 REV. 1
Type of Type of Acceptance
Remarks
Testing/ inspection bend Criteria
Bend body T& P KOC-MS-001 If mother pipe has been
laminations A p p en d i x D lamination tested, it need
not be repeated on bends
Repairs P API 5L PSL2 Body repairs are not allow ed
Wall thickness T& P API 5L PSL2 Full body including Intrados
and extrados
Diameter (bend body) P Table 1 and -
ASME B16.4
Diameter (ends) P Table 1 and -
ASME B16.49
Out of roundness P Table 1 and -
(ends) ASME B16.49
Out of rounds (body) P Table 1 and -
ASME B16.49
Linear dimensions P Table 1 and -
ASME B16.49
Bend angle P Table 1 and -
ASME B16.49
Bend radius P Table 1 and -
ASME B16.49
End squareness P Table 1 and -
ASME B16.49
Out of plane P Table 1 and -
ASME B16.49
End preparation and P As per clause 12.9 To be per ASME B16.25 f ig.
protection 2 illustration (a) or fig. 3,
illustration (a) as specified in
the bend data sheet
Gauging P As per clause 12.11 -
Residual magnetism P Maximum 2 mT To be measured at every
at ends bend
T-Test bend
P- Production bend

10.5 Destructive Tests for Qualification Test Bend

The destructive testing types and locations of samples shall be made as per
Table 3 of t his Specif ication.

Table 3 : Location of Test Pieces and Type of Test for Destructive Testing of
Test Bends (Refer to Fig. 2 which is identical to ASME B16.49 fig. 2 for
locations of testing)

Type of Test (Note 1) Location (Refer Fig. 1)

 Longitudinal tensile Tangent base metal (Note 2)
 Impact
 Through-thickness hardness
 Transverse tensile (Note 4) Tangent w eld (Note 2)
 Impact
 Through-thickness hardness
 Metallography
 Guided bend
 DOC. NO. KOC-MS-002 Page 17 of 29 REV. 1
Type of Test (Note 1) Location (Refer Fig. 1)
 Longitudinal tensile Transition zones base metal
 Impact
 Through-thickness hardness
 Metallography
 Transverse tensile (Note 3) (Note 4) Transition zones w eld
 Impact (Note 3)
 Longitudinal tensile Bend extrados base metal
 Impact
 Through-thickness hardness
 Longitudinal tensile Bend intrados base metal
 Impact
 Through-thickness hardness
 Transverse tensile (Note 4) Bend w eld
 Impact
 Through-thickness hardness
 Metallography
 Guided bend
Note (1): One test sample required. Acceptance criteria shall be as per KOC-MS-001 and
ASME B16.49. In case of conflict, the most stringent shall be applied.

Note (2): At KOC discretion, testing after bending may not be necessary if test results
are available for mother pipe and the tangent is not heat treated during
induction bending or subsequent heat treatment.

Note (3): These tests may be distributed betw een the tw o transition zones.

Note (4): For transverse specimens, the section from w hich the specimen is taken shall
not be flattened or otherw ise deformed. Flattening of tubular products to
permit testing does alter the material properties, generally non-uniformly, in the
flattened region w hich may affect test results. Refer to ASTM E8, ASTM A370
and BS EN ISO 100021-1.

10.6 Sour Service Testing

10.6.1 Testing for evaluation of resistance to hydrogen-induced cracking (HIC) shall be

made as per KOC Material Specification KOC-MS-001, Appendix-B. Test shall
be performed for all the heats used for the qualification of manufactured bends
made from longitudinal w elded and seamless pipes.

10.6.2 Test samples shall be taken from the extrados and the finish transition zones.
 DOC. NO. KOC-MS-002 Page 18 of 29 REV. 1

10.6.3 The HIC test shall meet the follow ing acceptance criteria; w ith each ratio being
the average for three samples per test specimen w hen tested in Solution A as
per NACE TM0284:

 Crack length ratio (CLR) ≤ 15 % ;

 Crack thickness ratio (CTR) ≤ 5 % .

 Crack sensitivity (surf ace) ratio (CSR) ≤ 2 %

10.6.4 Sulphide stress cracking test shall be made as per KOC-MS-001 and NACE TM
0177 on t he qualification test bend only. Test samples shall be taken from the
extrados and t he finish transition zones.

11.0 DIM ENSIONAL INSPECTION

11.1 General

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. The dimensional inspection shall include wall thickness, ovality, outside
diameter, inside diameter, bend radius, bend angle, off plane, centre to end
dimensions, bend end preparation, end squareness, pig gauge trials and surface
condition.

11.2 Wall Thickness

11.2.1 The manufacturer shall check the pipe w all thickness before and after
bending at the same locations. Wall thickness measurements by using
ultrasonic testing shall be in accordance w ith ASTM E797.

11.2.2 Wall thickness measurements shall be conducted at four (4) uniformly

spaced points around the circumference (including intrados and
extrados locations of bend) every 300mm (12 inch) or 15 degree,
w hichever is less along the length of the bend, in all cases including the
start, middle and stop of transition area, and also along the straight
portions (tangent lengths).

11.2.3 The w all thickness shall not be less than the specified minimum w all thickness
stated in the bend data sheet (basically, this specified minimum WT is that of
the related portion of pipeline of same steel grade to w hich the bend w ill be
connected later on).

11.2.4 The w all thickness plus its tolerance at bend ends (taking into account of the
specified nominal inside diameter) shall be such that the mismatch betw een
internal surfaces of bend and line pipe does not exceed 2.4 mm (0.094 in).
Excess material shall be machined back to obtain a taper angle of 10º maximum
at inside and 14º maximum at outside.
 DOC. NO. KOC-MS-002 Page 19 of 29 REV. 1

11.3 Out-of-Roundness (Ovality)

At any point throughout the body of bend, the difference betw een the
maximum and minimum outside diameters shall not exceed 2.5 % of t he
nominal mating pipe outside diameter. At ends of bend, the internal out -of-
roundness shall be in compliance w ith API 5L tolerances.

11.4 Outside Diameter

The outside diameter of each w elding end tolerance shall meet API 5L limits.
The diameter throughout t he bend body shall meet ovality tolerance.

11.5 Inside Diameter

The inside diameter t olerance at bevel face shall not exceed ± 1.6mm (± 0.063
inch). The inside diameter shall be checked by internal circumferential tape or
diameter tape. When caliper gauge is used, measurement shall be made
according to four (4) equispaced diameters from bottom of root face and the
average value shall give the actual inside diameter.

11.6 Bend Radius

Radius of bend shall be correct to w ithin ± 1% of the nominal radius, w ith a

maximum of ± 15mm (0.59 in).

11.7 Bend Angle

Bend angle shall be measured as the deviation of the straight portions at the
ends from a straight line (i.e. bend angle is not t he included angle). Bend angle
shall be accurate to w ithin ± 0.5º of the nominal bend angle.

11.8 Off-plane

The bend off -plane shall be measured by placing t he bend on a level surface.
Off-plane (in mm) shall not exceed A/9 in mm, w here A is the required bend
angle in degrees. When the calculated result is less than 5 mm (0.19 in), then
maximum off -plane shall be 5 mm (0.19 in).

11.9 Centre-to-End Dimensions

The tolerances of center-to-end dimensions shall be ± 5mm (0.19 in) for all
bends.

11.10 Bend End Preparation

Unless otherw ise specified in the bend data sheet, all bends shall be furnished
w ith plain ends, beveled to an angle of 30º (+ 5º to 0º) and root face of 1.6
mm (0.06 in) ± 0.8 mm (0.03 in). Beveling and taper (if any) shall be carried
 DOC. NO. KOC-MS-002 Page 20 of 29 REV. 1

out using proper machine only. Field const ruction involving mechanized w elding
may require other than API 5L end preparation. For that reason, the
manufacturer shall confirm the required type of end preparation before starting
end preparation. Bevel protectors shall be provided and installed by the
manufacturer for all bends.

11.11 End Squareness

Ends of bend shall be machined perpendicular to the longitudinal axis of the

bend. The out -of-squareness at the bend ends shall not exceed 1.6 mm (0.063
in).

11.12 Pig Gauge Trial

a) A pig gauge shall be passed freely through the full length of each bend.
The gauge shall have tw o equispaced and parallel 6 mm thick circular
metallic plates, each at least 96% of the connected pipeline nominal inside
diameter, separated by a rigid bar of tot al length equal t o the specified
nominal inside diameter.

b) If the gauging plates are stuck or damaged during t he test, the bend shall
be rejected.

11.13 Surface Conditions, Imperfections and Defects

a) All bends shall be free from visual def ects in the finished condit ion.
Surface roughness and w rinkles resulting from the pipe manufacturing
operations shall not be accepted.

b) All bends shall have smooth internal and external surfaces and shall be f ree
from heavy oxide or scale. At the manufacturer opt ion, t he internal surface
of bends shall be cleaned using suitable methods.

12.0 NON-DESTRUCTIVE TESTING

12.1 General

In addition to the applicable inspection and non - destructive testing performed

as per KOC-MS-001, the follow ing inspection and tests shall be made to all
manufactured bends.

12.2 Visual inspection

a) Visual inspection to detect surface imperfections shall be undertaken by

ASNT or equivalent standard qualified inspectors. Results of such
inspection shall be recorded and made available to the purchaser and/or
KOC inspectors.
 DOC. NO. KOC-MS-002 Page 21 of 29 REV. 1

b) All bends shall be grit blasted to a bright metal finish in accordance w ith
SSPC SP-6 before the visual inspection.

c) All internal and external surfaces shall be 100% visually inspected for
laminations, cracks, notches, gouges, arc burns, w rinkles or other
injurious defects. Surface imperfections shall be removed by grinding or
machining, providing that the w all thickness is not locally reduced below
the specified minimum w all thickness.

d) Internal visual inspection from inside the bend shall be performed for
bends of 508 mm (20 in) diameter and larger using illumination of at least
300 Lux (28 fc). For smaller sizes, the internal surfaces shall also be
inspected using suitable methods that have a demonstrated capacity of
detecting surface defects.

12.3 M agnetic Particle Testing

a) All bends shall be externally inspected by w et magnetic particle

inspection for injurious defects. For all bends, the bend body shall be
inspected over an arc of 90° both sides from the extrados in accordance
w ith ISO 13665, ASTM E709, ASME Sec V and ASME Sec VIII Div.1
Appendix 6. Should any injurious defects be found, the entire bend
surfaces shall be similarly inspected using the same MT method.

b) All examined surfaces shall be f ree of:

(i) cracks, laps, laminations and any relevant linear indications;
(ii) relevant round indications greater than 0.12” (3.0mm);
(iii) four or more relevant rounded indications in a line separated by
0.0625-in (1.5 mm) or less, edge t o edge.

c) All finished w eld bevels shall be inspected by w et magnetic particle

inspection.

13.0 M ARKING OF BENDS

13.1 Each bend shall be st enciled in w hite paint on t he outside surface w ith the
follow ing information. When t he bends are intended t o be coated externally,
the marking shall also be applied internally near one end.
 Manufacturer’ s name or trade mark
 Purchase order and it em number
 Project title
 Client (KOC) name
 Pipe steel grade and t ype (PSL2-API 5L)
 Nominal size and w all thickness
 Bend radius and angle
 Sour service
 Heat number or manufacturer’ s heat identif ication
 Post-bending heat treatment condition
 Any additional marking/shipping marks specified in t he purchase order
 DOC. NO. KOC-MS-002 Page 22 of 29 REV. 1

13.2 For bends of 100mm (4 in) and larger, markings shall be executed in
block capitals of minimum height 19 mm (0.75 in). For smaller bends,
stencil marking height shall be 10 mm (0.4 in) minimum. Identification
markings shall not be stenciled or painted on the w eld preparation.

14.0 HANDLING, TRANSPORT AND STORAGE

14.1 Suitable broad band non-metallic slings shall be used to load/unload bends.

14.2 Bends shall be adequately supported to prevent damage during transit.

14.3 All bends shall be protected from corrosion by applying clear coat
lacquer at both the inside and outside surfaces. The coating shall be
suitable for ocean transportation and shall be suitable for long term
atmospheric storage at black body temperature of 55º C.

14.4 Application of the lacquer shall be made after completing all testing
and visual inspection by the purchaser and/or KOC inspectors as
applicable.

14.5 Type of lacquer and application procedure shall be submitted for KOC
review and approval.

14.6 Storage shall be properly arranged to avoid accumulation of w ater

inside bends and to allow free circulation of air.

15.0 BEVEL PROTECTION

15.1 Bevel protectors shall be installed to protect the root face and bevel
against damage during subsequent handling, shipping and site w ork.

15.2 For 508 mm (20 in) and larger size bends, the protector shall be made
of a steel strip forming into a circular shape. The abutting ends of the
ring shall be fitted w ith steel w edge clasps. For bends smaller than
508 mm (20 in) size, bevel protector shall be of the steel or non-
metallic type as approved by KOC.

16.0 PACKING

Packing shall meet the requirements of KOC Standard KOC-G-004.

17.0 QUALITY ASSURANCE

17.1 The Manufacturer shall operate a quality system to ensure that

requirements of this Specification are achieved. KOC Standard KOC-
Q-014 shall be satisfied as applicable. The quality system shall be
based on ISO 9000, ISO 9001 and ISO 9004 or the API Q1.
 DOC. NO. KOC-MS-002 Page 23 of 29 REV. 1

17.2 The Manufacturer shall demonstrate compliance by providing a copy

of the accredited certificates as w ell as its quality manual to the
purchaser and KOC.

17.3 Verification of the Manufacturer’ s quality system is normally a part of

the pre qualification procedure; therefore it is not detailed in the core
text of this Specification.

18.0 DOCUM ENTATION AND CERTIFICATION

18.1 Documents Required Before Starting Production

a) Bending procedure
b) Qualification test procedure and requirements
c) Welding and repair w elding procedures (if applicable)
d) Heat treatment procedure
e) Mechanical testing procedures
f) NDT procedures
g) Cleaning/abrasive blasting procedures
h) HIC and SSC procedures
i) Dimensional examinat ion procedure
j) Schedule of qualification and production
k) Coating procedures
l) Marking procedure
m) Quality plan and ITP

18.2 M anufacturing Record Book (M RB) Documents

The MRB shall include the follow ing documents:

a) Qualification test results

This shall include but not limited to the mechanical test results, HIC, SSC,
dimensional inspection, gauging inspection, data of mother pipe used for
the test, thickness measurements and any supplementary tests.

b) Bends certificates

The required Inspection test certificate to support the delivered bends shall
be type 3.1 according to EN 10204 and ISO 10474 standards. Reports and
certificates shall include but not limited to the follow ing:
DOC. NO. KOC-MS-002 Page 24 of 29 REV. 1

(i) Bends tally sheets show ing mother pipe numbers

(ii) Mother pipes details and certificates (Steel grade, w all thickness, heat
and product analysis including CE and/or Pcm), mechanical and
chemical data, etc.
(iii) Dimensional and gauging inspection results
(iv) NDT reports and certificates
(v) Heat treatment report s, charts and certificates
(vi) Approved and marked ITPs
c) Contractual documentation

This part of t he MRB shall include the f ollow ing:

(i) Unpriced purchase orders

(ii) All approved final procedures
(iii) Other deliverables that have been approved during the pre-inspection
meeting or any other meetings
(iv) Amendments to the purchase orders, if any
(v) Approved concession requests, if any
(vi) Non conformance reports
(vii) Inspection release and shipping release
(viii) Shipping and marking details
DOC. NO. KOC-MS-002 Page 25 of 29 REV. 1

APPENDIX 1: BEND DATA SHEET

Induction Bend Data Sheet Page 1 of 2

KOC Project No. Contractor: ……………………. Prepared by: ……………………….

…………............ ……………………………………
Date: ……………
Project Title: Enquiry/ PO. No.: ……….
……………….
Bend Specification: KOC-MS-002 & ASME B16.49
M other Pipe Specification: KOC-MS-001 & API 5L Other:
……………………………………….
Bend Procedure Qualification Test: Required Waived
When bend procedure qualification is required, it shall be made for each representative heat,
grade, size and w all thickness)

Design Conditions

1. Bend to be welded to: Size ………… Wall Thickness …………Grade …………

2. Quantity of Bends: …………

3. Minimum Wall thickness of the Bend at the Extrados ……………..

4. Bend Radius: …………………… Nominal Diameter …………………

5. Bend Angle ……………………. Tangent Length: ……………… (Both ends One End )

6. Minimum Centerline Length required between bends (S-bend only): ………………..

7. Field Segmental Bend: …………… Yes No

8. Minimum I.D. at Ends and in Body: …………………

9. End Preparation: Standard API 5L ASME B16.25 ASME B31.8 (Appendix-I)

ASME B31.4 (clause 434.8.6) Other (specify)

10. Notch Toughness Properties Acceptance Criteria: …………………

11. Temperature of Charpy Impact Testing: ……………………………..

Coating Required Not required

Coating Type Required: …………………………..

M arking: ……………………..
Special Shipping M arking: …………………

M ill Inspection by: The Buyer Kuwait Oil Company Others (Specify)

Remarks:
………………………………………………………………………....
………………………………………………………………………………………………………………
DOC. NO. KOC-MS-002 Page 26 of 29 REV. 1

This data sheet should be filled by the KOC project in charge pipelines engineers and/or the engineering
contractor professionals. All purchase orders shall be attached with the relevant filled data sheets.

NB : This sketch is part of the data sheet

DOC. NO. KOC-MS-002 Page 27 of 29 REV. 1

APPENDIX 2 “FIGURES”

Figure 1: Nomenclatures of Induction Bend (From ASME B16.49)

DOC. NO. KOC-MS-002 Page 28 of 29 REV. 1

ACKNOWLEDGEM ENT

This Material Specification has been approved by the KOC Standards Technical
Committee (STC) consisting of the follow ing:

Mr. Hamzah Ahmad Standards Team Chairman

Mr. Mohammad Emam Insp. & Corr. Team (S&E) Deputy Chairman
Mr. S. Kumar Standards Team Secretary/ Member
Mr. A. Unnikrishnan Standards Team Member
Mr. N. Ramanathan Major Projects Team -IV Member
Mr. Daniel Pino Utilities Team Member
Mr. Abdul R. Al-Shamari Insp. & Corr. (N&WK) Team Member
Mr. Mohd. Aslam Imadi Design Team Member
Mr. G. Unnikrishnan Design Team Member
Mr. Haitham Aboughaith Gen. Project Team Member
Mr. Gopal Murthy Opns. Tech. Svcs. (WK) Team Member
Mr. Richard Arthur Info. System Planning Team Member
Mr. Nandkumar Aravind HSE Systems Team Member
Mr. Abdulla AL-Yousef Project Mgmt. Team (NK) Member

The draft of this Material Specification had been circulated to the KOC User Teams
for review and the responses w ere received from the follow ing:

ENGINEERING GROUP HSE GROUP

Team Leader Design Team Leader Safety

MAJOR PROJECTS GROUPS (I & II) AHMADI SERVICES GROUP

Team Leader Major Proj. IV Team Leader Utilities

Team Leader Project Design

DRILLING OPNS. GROUP GAS MGMT GROUP

Team Leader Drlg.&W/Over Tech.Svcs.(I) Team Leader Consumer Netw orks

NORTH KUWAIT DIRECTORATE WEST KUWAIT DIRECTORATE

Team Leader HSE (NK) Team Leader HSE (WK)

Task Force Responsible for this M aterial Specification (M S)

The Preparation of t his Material Specification (MS) has been entrusted by the
Standards Technical Committee (STC) to the Task Force No (TF-MS/02) comprising
of the f ollow ing members:

Mr. Mohd. Emam Insp. & Corr. Team (S&E) TF Leader Tel. No. 65254
Mr. Sayed Abul-Khair Insp. & Corr. Team (S&E) Author/Member Tel. No. 61455
Mr. Tareq Al-Masoud Insp. & Corr. Team (N&W) Member Tel. No. 61176
DOC. NO. KOC-MS-002 Page 29 of 29 REV. 1

Mr. N. Ramanathan Major Projects Team -IV Member Tel. No. 66960
Mr. A. K. Ghosh Design Team Member Tel. No. 61768
Mr. Richard Eltringham PMC (Fluor) Member Tel. No. 61301