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BAHRAIN PIPELINE PROJECT

( ONSHORE SECTION )

RE DOC. NO.
METHOD STATEMENT FOR PIPE COLD PAGE: 1 of 15
17BP0978- CB-001 BENDING FOR INSTALLTION OF PIPELINES
REV.: 00

ARAMCO OVERSEAS COMPANY B.V (AOC) and


BAHRAIN PETROLEUM COMPANY B.S.C (CLOSED) (BAPCO)

BAHRAIN PIPELINE PROJECT

METHOD STATEMENT FOR PIPE COLD BENDING


FOR INSTALLATION OF PIPELINES

RAMSIS ENGINEERING COMPANY


P.O. Box 28967, East Riffa Kingdom of Bahrain

Issued for Review /


0 Ahmed Ali Nehal Paresh 28/03/2017
Comments
PREPD
REV. DESCRIPTION BY
REVD BY APPRD BY DATE


BAHRAIN PIPELINE PROJECT
( ONSHORE SECTION )

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REVISION CONTROL SHEET

Revision
Date Page Nos. Description
No.

0 28/03/2017 15 Issued for Review / Comments


BAHRAIN PIPELINE PROJECT
( ONSHORE SECTION )

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1) INTRODUCTION

A new pipeline is being constructed with related facilities from Abqaiq Plant to BAPCO
Refinerythrough Qurayyahutilizinganexistingpipelinecorridor fromAbqaiq to Qurayyah
andthenfromBahrainshorelinetoBAPCORefinery.Theproposedpipelineshallreplacethe
existingcrudeoilsupplysystem.Theproposedpipelineshallbebuiltaccordingtocontract
requirements.

2) ScopeofFacilities

This LSTK Package is for Engineering Design, Procurement, Fabrication and Installation of
Offshore Segment of 30 Bahrain AB4 Pipeline, Fiber Optic Cable, ICCP and all other
associated items. The extent of the Pipeline scope is from the Onshore Isolating Flange in
QurayyahSaudiArabiatotheOnshoreIsolatingFlangeinAlJazair,Bahrain.Theextentofthe
FiberOpticCablescopeisfromtheRTUshelterinsidetheQurayyahValveStationtotheRTU
ShelterinsidetheAlJazairValveStation.TheOnshoreSegmentofthepipelineandfiberoptic
cable in Saudi Arabia is by the Saudi Onshore Contractor. The Onshore Segment of the
pipelineandfiberopticcableinBahrainisbytheBahrainOnshoreContractor.

2.1 Pipeline

ThenewSaudiBahrainAB4pipelineis30outsidediameterandapproximately112.7km
long,fromthescraperlauncheratAbqaiqPlantinSaudiArabiatotheScraperReceiverat
BAPCOs Refinery in Bahrain. The pipeline is being constructed in three segments
simultaneously
Segment1:OnshoreSaudiArabiaFromScraperLauncheratAbqaiqPlanttoIsolatingFlange
QurayyahSaudiArabia,approximately43.636KM.
Segment2:OffshoreSaudiArabiaacrosstheGulfofSalwa/BahrainFromIsolatingFlangein
Qurayyah Saudi Arabia to Isolating Flange Al Jazair Bahrain, approximately 40.906 KM.
(CONTRACTORNPCCSCOPE)
Segment 3: Onshore Bahrain From Isolating Flange AlJazair Bahrain to BAPCO Receiver
Bahrain,approximately28.145KM.

BriefscopeofworkfortheonshoreworksatAlJazairinBAHRAIN
ThebriefscopeofworkfortheonshoreworksatALJAZAIRINBAHRAINsubcontractedtoM/sRAMSIS
asfollows:


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a. Trenching, burial of Onshore Pipeline including laying of pipeline and tiein with offshore
pipelineatlandingpointforapproximatelengthof383LM

b. Trenching,burialofOnshoreCableincludinglayingofcableandsplicingtheapproximatelength
ofthecabletobelaidis400LM

c. Procurement,construction&Installationof30thrustAnchoratSaudiOnshore.

d. Providing all required civil works, Installation, testing and commissioning of Temporary CP
system&permanentICCPsystemfortheburiedportionofthepipelineandalsosupplyand
installSecurityfenceforCPstation.

e. AssistanceforMainContractor(NPCC)duringpipelineHydrotestingandPrecommissioning

f. Assistance for Main Contractor (NPCC) for the Shore pull of 30 pipeline and FOC cable at
Qurrayah,SaudiArabia

2.2 SubmarineFibreOpticCable

AFiberOpticcableisinstalledfromAbqaiqplanttoBAPCOsrefineryrunningparalleltothepipeline.
Thefiberopticcableisusedforleakdetection,controlandcommunication.FortheOffshoreSegment
2asubmarinefiberopticcableisinstalledfromtheRTUshelterinsidetheQurayyahvalvestationto
theBahrainRTUshelterinsidetheBahrainnearshorevalvestation.


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Offshore Segment 2 Saudi Bahrain Pipeline and Submarine FOC

Pipeline Schematic Diagram

30 AB-4 Pipeline Schematic Diagram

TableofContents
1Scope:..........................................................................................................................................7
2Responsibilities...........................................................................................................................7


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3References:..................................................................................................................................7
4Documents(drawings,sketchesetc.)........................................................................................8
5SequenceofWork:......................................................................................................................8
6GeneralRequirements:...............................................................................................................8
7ColdBendingDemonstration..................................................................................................10
8BendingCalculation.................................................................................................................10
9Bendingbythreerollpush......................................................................................................11
10Resources:................................................................................................................................13
11Riskrating.................................................................................................................................13
12QA/QCRequirements............................................................................................................14
13Approvals.................................................................................................................................14
14Attachment.................................................................................Error!Bookmarknotdefined.


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1Scope:
Thismethodstatementdefinestherequirementsforpipecoldbendingworks.

2Responsibilities
RAMSIS
ProjectManager
Isresponsiblefortheinitiation,planning,andintegrationofcompletemanagementprocess,to
deliverallthedeliverableswithdueconsiderationforquality,costandtime.Hewillbeleadingthe
constructionteamandisresponsibleforallsiteandoffsiteactivities.

ProjectEngineer
IsresponsiblefortheimplementationofMethodStatementandensuresthathisteamofengineers
andforemenareawareofthemethodstatementandtheprojectengineerwillensureallthe
resourcesareavailabletocarryouttheworkasplannedandwithoutanydelay.

SiteEngineer
Isresponsibleforensuringthatalltheworksareexecutedinaccordancewiththecontract
specifications,drawingsandincompliancewiththismethodstatement,workswillbeofferedto
clientinspection.

QCInspector
Isresponsibletoensureworkhasbeendoneasperspecificationanddrawings,inspectionsshallbe
doneasperQualityControlProcedureandtheInspectionandTestPlan,workswillbeofferedfor
ConsultantsInspection.

SafetyOfficer
Isresponsibletoensurethatallsafetyprecautionsareinplace,andthatallpersonnelonsiteare
usingPersonalProtectiveEquipmentsuchashardhat,Gloves,Shoes,andReflectiveJacket

SiteForeman
Isresponsiblefororganizingtools,machinery,materialsandcontractors.Hewillsupervisethe
constructionactivitiesaswellasidentifymaterialsandequipmentthatmayberequiredtocomplete
thejob.

3References:
ASME31.4:pipelinetransportationsystemsforliquidHydrocarbonsandOtherLiquids,

ASME31.8:Gastransmissionanddistributionpipingsystems.

SAES450:constructionofOnlandandnearshorepipelines

SAICL2114:Inspectionoffieldbendingforpipeline.


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4Documents(drawings,sketchesetc.)
Relevantdrawings:BA078238(RefertoDetail2)

5SequenceofWork:
Preparatorywork:

RAMSIShascarriedoutpreconstructionsurveyofallpipelinecoldbendingonthepipeline
route.
Uponapproval,RAMSISwillpreparealltherequiredmaterials,manpower,andequipments
andsafetysignboardtoexecutetheactivity.

6GeneralRequirements:
Allcoldbendingofpipesshallbeaccordingtothefollowingrequirements:

UndernocircumstanceshallthestartandENDofthebendbecloserthan1.5mfromtheend
ofthepipeorwithin600mmofgirthweld.
Thetangentendsofeachbendsshallbestraightandshallnotbesubjectedinanywaytothe
coldbendingoperation,
Pipewithlongitudinalweldshallbebentinsuchwaythatthelongitudinalweldliesina
planethroughtheneutralaxisofbend(fig1)thepipeshallbeplacedwiththelongitudinal
weldsintheupperquadrants.

Pipebendingmachineshallbecapableofpreservingcrosssectionalshapeofthepipe,
providesbendswithoutwrinkles,andbucklesstretching.
Bendingmachineshallbeequippedwithpads,diesandrollershavingsoftsurfacetoavoid
orminimizedamagetothepipesurface.


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Thepipeshallbeinstalled,positioningthelongitudinalweldintheupperquadrants.
Ifhorizontaldeviationsaretobeachievedbyjoiningtwoormoreadjacentbends,then
bendingofthepipelengthshallbemadebypositioningthelongitudinalweldsalternately
70mmaboveandbelowtheplanepassingthroughtheneutralaxis.
Ensurethatthebendwithlongitudinalweldschosenforjoiningtwoormoreadjacentbends
shallhavetheirlongitudinalseamsdisplacedbyabout150mmstaggered,andalwaysoccur
intheupperquadrants.
Whereverticalbendsaretobeformedbyjoiningtwoormoreadjacentbendsthe
longitudinalweldsshallbepositionedalternatelytotheleftandrightoftheplanepassing
throughthenaturalaxis.
Foremanshallmarktangentoneachendofpipe,priortoinsertingpipeintothemachine.
Uponcompletionofmarkingpipeshallbeinsertedintothepipebendingmachine.Cranewill
facilitatebendingofpipetobebentandfeedpipeintobendingmachine.
Allbendingoperationwillbesupervisedbyqualifiedandexperiencedbendingstaffwhowill
coordinatewiththesitesupervisorandsurveyor.
Thebendshallbedistributedthroughoutasgreatalengthofpipeaspossible.
Inonefulllengthofpipe,afterdeductingtheavailablepipebendingarcshallbedetermined.
Basedonthelengthofthepipebendingarc,numberofbite(press)andmaximumbending
angletobeachievedshallbedetermined.
Thenumberofbiteanddistancebetweenbitestobemadeshallbeevenlydistributed
consideringthetotalangletobeachievedtosuitethegroundprofile.
Allformedbendsshallbewithoutwrinkles,bucklesandstretching.
Thepads,diesandrollsofthebendingequipmentshallhaverelativelysoftsurfacetoavoid
damagetotheline.Whereapplicable,fullyretainingbendingshoesshallbeused.The
tangentendsofeachbendshallbestraightandshallnothavebeensubjectedinanywayto
thecoldbendingoperation.Thelengthofthestraightsectionshallbepreservedtopermit
easeofalignmentandfieldwelding.Undernocircumstanceshallthestart/endofthebend
beanycloserthan1.5mfromthepipeendorwithin1mofagirthweld.
Ovalisationofacoldfieldbendingshallnotexceed1.0percentofthenominalpipeline
diameteratanypoint.RAMSISQCpersonnelshallcarryoutadimensionalcheckonall
bends,bypassingagaugeconsistingoftwodiscsofdiameterequalto95percentofthe
nominalinternaldiameterofthepipe,connectedrigidlytogetheratdistanceequalto350
mm.ThedimensionalchecksshallbecarriedoutandwitnessedbyBAPCOduringeachcold
bending.
Bendshallnotmadecloserthan600mmfromtheedgeofthelinepipejoint(locationoffield
circumferentialweld).
ThebiteangleandspacingofthebendshallconformtoSAESL450
BendingdetailsshallbepreparedinaccordancewiththeIFCandinconformancewithSAES
L450
Pipediameteratanypointoftheperformedbendshallnotreducebymorethan2.5%ofthe
nominalpipediameter.


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Maximumpermissiblelocalizedbendorbiteatoneplaceonthepipeandtheminimum
spacingofsuchbitesconformswithSAESL450App.Btable1.
Ensurethatbendingmachinewillbecapableaccordingtothepipesizeandfield
requirements.

7ColdBendingDemonstration
Priortocommencementofcoldbending,thefirstbendingoperationshallbeconsiderto
demonstrationoftheprocedure,forwhichtheclientrepresentativesaretoinformedfor
witnessing

8BendingCalculation
Undernocircumstancesshallthestart&endofthebendcanbecloserthan1.5mfrom
theendofthepipe.

Itiscalculatedasfollowsforvariouspipedimeter.

Fora3040Dbend,thelengthofpiperequiredisasfollows:

Angleofbend=arclength/radius

Arclength=(121.51.5)=9m

Radius=40D=40x30x(25.4/1000)=30.48m

Angleofbend=360degreesx(9/[2x30.48])=16.93degree

Lengthofpiperequiredforonedegreebend0.53meter

Coldbendingmethodology
1bendingByAutoMachine
Handling,lifting,positioningofthepipeintobendingmachinesaddleshallbe
carriedoutusingcraneequippedwithwidenonmetallicliftingbelts(Choker
belt),takingcaretheproperpositionofpipelongitudinalweldisasper
specificationandasdescribedabove.
Craneboomshallloweroneendofthepipeontorollerandthepipeismoved
intothebendingmachinehalfwaywherebythemandrelwillbeloadedandsetto
desiredbendposition,pipeshallnotbemovedbeyondfrontedgeofthedie,
mandrelshallbeaccuratelypositionedbeneathdieandremainsthereduring
eachbend,ifitisnotdone,pipewallbucklingorotherdamageswilloccur.
Thecablehookshallbeattachedtothestiffbackendofthepipe,soasto
advancepipebywinch.
Slowlytensionthewinchcableuntilthepipeisproperlylocatedforthefirst
bendingoperation,underthedie,atthepointwherethebendistocommence.


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Pinupshoeisraiseduntilthepipetouchesthelowestpointofthecurvatureof
thedieandengagesthepipewhereasstiffbackinboardcylinderpushesthepipe
againstthedie.
Thedistancefromthelowerfrontofthedietothetopofthepipeandthe
distancefromrearofthedietothetopofthepipeshouldbeequal.
Withthedieactingasfulcrum,outboardcylinderpushestheendofthestiffback
up,bendingthepipe.
Aftereachbendingoperation,thepipeismovedthroughthemachineincrement
andtheoperationrepeateduntilthedesiredangleofbendisachieved.
Duringthecourseofbendingandontheconclusionofbendingoperationthe
angleofbendachievedischeckedwithclinometers.
Oncompletionofbendingallbendsshallbetestedwiththegaugingplate.
Thosebendsfoundtobenonconfirming,i.e.thegaugingplatedoesnotpass
through,shallbeidentifiedbythebendingsupervisorandstoredseparately.
Supervisorshallcheckpipeexternalsurface,tangentlength,passingofgauge
plateandensurethatitisaspertherequirementofspecificationforfieldcold
bendsvideTPTBWM00372SOWA4Rev3clauseno.8.10.2.

Allthebendpipesshallbeidentifiedandmarkedclearlywithmarkerasfollows:
Relevantpipenumber,totalangleofbend,chainagelocation,typeofbendand
directionofbendingshouldbeclearlywrittenonbentpipeandidentifiedonthe
bendingrecordsbysupervisor/Forman.
Abendingrecordistobemaintainedforallpipesbentonaday,indicatingpipe
number,heatnumber,lengthofpipe,diameter,wallthickness,angle(degree),
includingthenumberofPullsineachpipe.
Beforecuttingofanypipelength,pipeend,etc.,thepipeidentificationnumber
shallbetransferredtotheresultingpipes,pupsetc.Sothatallpiecesare
identifiedbyindeliblemarksandidentifiedinthebendingrecords.Minimumpup
lengthwillbe1.5meter.

9Bendingbythreerollpush
Threerollpushprocessisfreefrombeingprocessanditisusetocreategeometriesthatconsistof
severalbendingcurves.Herethemetalbendprofileisguidedbetweentowrolls,thebendingaswell
assupportingroll.Theformingrollisthethirdrollandthishelpsdefinetheradiusofthebendasthe
photobelow.


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Itdoesthisofopposingrollers,inwhichapipeslottedthroughandworkedbackandforth,untilthe
desiredcurvatureisobtained.Typicallypipeisfedthroughrollersinatriangulararrangements;the
arcofthecircleisdeterminedbyadjustmenttosecondopposingroller.

Preoperation:

Ensuregoodhousekeepinginworkarea.
Donotwearlooseclothingorjewelry.
Inspectequipmentbeforeuse,fordamagedpartsandcords.
Ensurepipebendisdisengagedbeforefittingtheappropriatedie.

Operationalsafety:

Lockoffthehydraulicbleeder.
Placethelengthofthepipeagainstthedie.
Operatorusespumpingactiononhandleuntilpipeisfirmagainsttherollers.

Postoperation:

Alwaysisolatetoolbeforeservicingorwhennotinuse.
Ensureyoucleanupworkarea.
Placealltoolsusedbackwheretheybelong.


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10Resources:
Manpower
1.1 MechanicalSupervisor
1.2 QCinspector
1.3 Safetyofficer
1.4 MechanicalForman
1.5 Pipefitter
1.6 Bendingmachineoperator
1.7 Rigging
1.8 Helpers
1.9 Drivers/operators

Equipment
2.1Crane
2.2BendingMachine
2.3Hiab
2.4Inclinometer
2.5Othermeasurementstools

11Riskrating
Supervision
Sitesupervisorshallberesponsibleforsupervisionofallactivities.
SafetyofficersshallberesponsibleformonitoringtheHSErequirements.
Superintendentshallhaverandomcheckingandsupervisionofthisactivitythroughoutthe
duration.

HSERequirements
Safetyofficershallmonitorthework.
Allmembersoftheteamshallundergosafetyinductionrelevantforthejob.Thisshall
includeEmergencyResponseProcedure.
AllworkmenshallhavePPEDeterminedforthejob(viz.coverall,helmet,safetyshoes,hand
gloves,etc.)
ConductToolBoxTalktobriefallconcernedaboutnatureofjob,riskinvolved,
contingencyplan,courseofactionincaseofemergencyetc.
Onlyexperienced/skilledpersonnelshallbedeployedforthejob.
Insistongoodhousekeepingatalltime.
Allliftingtacklesshallhavevalidtestcertificatesandcoloratalltime.
FireExtinguishersshallbeavailablefortheworkforceatalltimes.
Numberofpeopleshallberestrictedtobareminimumrequiredfortheoperation.


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Noliftingoperationshallbeperformed,ifwindspeedexceeds10m/s
Noliftingoperationshallbeperformedwithin10meterof11&33KVOHL.
JSPshallbepreparedforliftingoperation.
Requiredheatstressmanagement/wellfareshallbeprovided.

12QA/QCRequirements
Inspectionreporttobepreparedforthebendingoperationaspertheattachedofthe
MachineCategory.

13Approvals
TherelevantapprovalshallbetakenfromBAPCOpriortopipecoldbendingfortransfer
lines.
Therelevantapprovaldocumentsrequiredwillbesubmittedinadvancepriortostartingof
pipecoldbendingfortransferlinesandalsowillbesubmittedwithpermit.

14Attachments
PIPEBENDINGREPORT


BAHRAIN PIPELINE PROJECT
OFFSHORE E&P AND BAHRAIN
PIPELINE PROJECT OFFSHORE
INSTALLATION CONT. NO : 6600036114
(OOK) & 6600036207 (IK)
RAMSIS FORMAT. NO. ReportNo:REBPCB009
RE-X-10001 REPORTFORFIELDCOLD
Rev00 BENDINGOFLINEPIPE Date27/04/2017



PipelineDescription:ABPIPELINEDRAWINGNO:BA084709SHT1to15

MaterialGrade:API5LX60GrPSL2InternalMandrel:Yes/No):yes

GaugingPlateSize:95%ofPipedia.


ColdBendingMethodStatementhasbeenreviewedandapproved(Yes/No):YES

ColdBendingCalculationhavebeenreviewedandapproved(Yes/No):YES
BendLocationisasperapprovedalignmentsheet(Yes/No)YES

BendingMachineanditsaccessoriesareingoodconditionandsuitablecapacity(Yes/No)YES
VERIFICATIONOFBENDSECTION

S/NO PIPE HEATNO LENGTH DIA Wall BEND SEG COATINGVISHUAL STRAIGHT GAUGING
NO
(M) (Inch) Thk. ANGLE NO ENDS PASSED
(mm) (M)

No Damaged Location YES NO
Damage of
Damage

1 A001 S617123 12mtr 30" 14.7mm 4.17 B NO NO NO 1.5&2.6 YES









ACCEPTENCENCRITERIA:Locationoflongseamweld70mmaboveandbelowneutralaxisseparatedby150mm
betweentwowelds120ofupperquadrants
NocoatingpipeDamages
InternalDiameterbyGauging

SHOPSUPERIORINTENT QUALITY BAPCO



NAME:

SIGNATURE:

DATE: