Statoil governing document

Requirements for bending and flaring of piping

Technical and professional requirements, TR1969, Final Ver. 2, Valid from 2006-09-29
Publisher/follow-up: Chiefengineer Materials Technology
Classification: Open
Validity area:
Statoil Group/All locations/All value chains/On- and offshore

1 Objective, target group and warrant ..............................................................................................3

1.1 Objective .............................................................................................................................................3
1.2 Warrant ...............................................................................................................................................3
2 Requirements.....................................................................................................................................3
2.1 General................................................................................................................................................3
2.2 Requirements for pipes for cold bending and flaring..........................................................................3
3 Cold Bending .....................................................................................................................................4
3.1 Wall Thickness ...................................................................................................................................4
3.2 Bending of Welded Pipe .....................................................................................................................4
3.3 Limitations and Special Requirements ...............................................................................................4
3.4 Welding...............................................................................................................................................4
3.5 Bending Procedure..............................................................................................................................4
3.6 Qualification .......................................................................................................................................5
3.7 Non Destructive Testing in production...............................................................................................5
3.8 Production Testing ..............................................................................................................................6
3.9 Certification ........................................................................................................................................7
3.10 Dimensional Test ................................................................................................................................7
4 Induction Bending.............................................................................................................................7
4.1 Wall Thickness ...................................................................................................................................7
4.2 Bending of Welded Pipe .....................................................................................................................7
4.3 Post Bending Heat Treatment .............................................................................................................7
4.4 Bending Procedure..............................................................................................................................7
4.5 Surface conditions...............................................................................................................................8
4.6 Qualification .......................................................................................................................................8
4.7 Non Destructive Testing for production .............................................................................................9
4.8 Certification ........................................................................................................................................9
4.9 Dimensional Test ................................................................................................................................9
5 Flaring................................................................................................................................................9
5.1 Design requirements ...........................................................................................................................9
5.2 Post flaring heat treatment ................................................................................................................10
5.3 Flaring Procedure..............................................................................................................................10
5.4 Qualifications....................................................................................................................................10
5.5 Non Destructive Testing for production ...........................................................................................10
5.6 Production Testing ............................................................................................................................11
5.7 Certification ......................................................................................................................................11
5.8 Dimensional Test ..............................................................................................................................11
6 Definitions........................................................................................................................................12
7 Modifications to previous version..................................................................................................12
8 References........................................................................................................................................12
App A Limitations and special requirements for cold bent pipes. .........................................................13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

1 Objective, target group and warrant

1.1 Objective

The purpose of this document is to ensure that cold bending, induction bending and flaring of piping is
performed in a consistent manner and meet minimum Company requirements for the products.

1.2 Warrant

“Project Development” (AR05) (Statoil group / All locations / On- and offshore).
“Operations, maintenance and modifications” (AR12) (Statoil group / All locations / On- and
offshore).

2 Requirements

2.1 General

This document give the requirements for cold bending, induction bending and flaring of piping items
designed in accordance with TR2000 (L-SP-200) and ASME B31.3. In case the document is used in
connection with other design standards, the conditions and requirements must be agreed with
Company.

The preferred bending radius for cold bending is 3 x D, however other bending radii may be
acceptable.

A manufacturing procedure for each site, detailing all requirements, shall be prepared. The following
criteria are applicable:

• All bending and flaring shall be performed in accordance with a written procedure. The procedure
shall be qualified when specified.
• Tubing and small bore piping (Ø < 1”) may be bent without a qualified procedure.
• The equipment and process shall be qualified and maintained to ensure that the material properties
fulfil the requirements for piping fabrication. The procedures and qualification records shall be
available for review.
• The bending shall as a minimum fulfil the requirements in ASME B31.3 and the requirements of
this specification.

It is the responsibility of the manufacturer to ensure that all applicable requirements of the Pressure
Equipment Directive 97/23/EC are fulfilled, when relevant.

2.2 Requirements for pipes for cold bending and flaring

Pipes for cold bending and flaring shall fulfil the requirements in the applicable MDS, ESK and
reference standard.

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 3 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

Titanium pipes, ASTM B861/B862, gr. 2, shall have a minimum elongation of A5 > 25% (A4 >27%).

Pipes selected for production bending shall have an elongation (stated in the material certificate) which
is larger than the sum of the required minimum elongation after bending (10 %) and the reduction in
elongation recorded during the qualification.

3 Cold Bending

3.1 Wall Thickness

The design pressure of the relevant piping class shall be used for wall thickness calculations. The
strength increase of cold bent pipe shall not be included in the pipe wall thickness calculations.

Minimum wall thickness at extrados shall be calculated from nominal wall thickness minus the
undertolerance.

3.2 Bending of Welded Pipe

The longitudinal weld of welded pipes shall be located in a zone ±40° from the bend neutral axis.

3.3 Limitations and Special Requirements

The limitations and/or additional testing for the different material types related to cold forming are
given in appendix A. The maximum permitted pipe diameter for cold bending is 8”.

When solution annealing heat treatment is required, the heat treatment manufacturer shall be qualified
according to Norsok M-650. This does not apply for heat treatment of 316(L) SS type of materials.

3.4 Welding

No welding shall be performed in the plastically deformed zone nor closer than 2 x WT, minimum 30
mm, to this zone unless properly qualified on cold formed material.

3.5 Bending Procedure

All cold forming shall be performed in accordance with a written procedure detailing:

• Material and applicable MDS

• Diameter
• Wall thickness after bending (min. / max.)
• Name and type of forming equipment
• Relevant forming parameters
• Inspection and NDT of bends, including acceptance criteria
• Any post bending heat treatment
• Production testing

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 4 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

Maximum fibre elongation and deformation shall be calculated for each procedure.

Bending procedures for piping with diameters 1” and larger shall be qualified.

3.6 Qualification

The following essential variables shall apply for bend qualification:

Material : Each quality and grade / UNS number

Type of Pipe : Welded pipe qualifies seamless, but not vice versa
Bend Radius : One radius qualifies all larger radii
Diameter [D] : + 50% - -50%
Wall Thickness [t] : + 25 % - -50 %
Longitudinal Weld : One angle from the neutral axis qualifies all lower
Position angles
Heat Treatment : Any change in PBHT procedure
Type of equipment : Any change

The qualification bend shall be at least 90°. Specimens for destructive testing shall be sampled from
the area exposed to the most severe deformation. For welded pipe both the weld and base material
shall be tested.

The material properties of the qualification bend shall be verified by testing after bending. All tests
specified in the applicable MDS, ESK and reference standard for pipe and App. A of this document
shall be performed. Longitudinal tensile testing shall be performed to verify retained elongation.

Acceptance criteria shall be according to the applicable MDS, ESK and reference standard for pipe and
appendix A of this document with the following additions:

• Impact toughness shall satisfy Norsok M-601 table 1.

• Hardness values shall comply with App. A.
• The qualification bend shall be subjected to 100 % visual examination and 100 % MT or PT as
applicable. For welded pipe the weld area shall be 100 % RT after bending. The use of UT as a
substitute for RT may be acceptable for large wall thicknesses. NDT procedures and acceptance
criteria shall be according to the reference standards for pipes and fittings as listed in the MDS.
• The out-of-roundness, wall thickness and other dimensional requirements of the qualification bend
shall be checked before and after bending. The requirements of the design code shall be met.

Documentation of the qualification shall be:

• Record of bending method, bending parameters and equipment used.

• Record of bending radius and angle
• Report with results of all tests performed.
• Material certificate

3.7 Non Destructive Testing in production

The NDT requirements for cold forming shall be as stated below. The same NDT groups as for M-601

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 5 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

are used. For MT and PT the acceptance criteria shall be in accordance with ASME VIII, Div.1,
Appendix 6 and 8 respectively.

NDT SERVICE PRESSURE STARTING PIPE EXTENT OF

GROUP RATING NDT [%]4)
Visual MT/PT
1 Non-flammable PN 20 Seamless 100 2 1)
and non-toxic (# 150) Welded 100 10 2) 3))
fluids only
2 All systems PN 20 and 50 Seamless 100 2 1)
except those in (#150 and # 300) Welded 100 10 2) 3)
NDT group 1
3 All systems ≥ PN 100 Welded 100 102)
(# 600 and above) Seamless 100 5 1)

Notes:
1) The percentage defines the number of bends of each pipe size, wall thickness and type of material
at each fabrication site, which shall be examined 100 %. The bends to be examined shall be
uniformly distributed throughout the manufacture and shall be representative for the production.
Sub-contractors to the main sites are in this respect considered separate sites.

2) The weld in 10 % of the number of bends of each pipe size, wall thickness and type of material at
each fabrication site shall be examined 100 %. Formed area in the base material shall be examined
to the same extent as for seamless pipe within the same NDT group. If no defects are found in the
weld area in 20 subsequent examined bends per type of material, pipe size and wall thickness, the
extent of weld examination may be reduced to 5 % of the number of those bends. The bends to be
examined shall be uniformly distributed and shall be representative for the production. Sub-
contractors to the main sites are in this respect considered separate sites.

3) For 22% Cr and 25% Cr duplex SS bends the weld area in the 3 first produced bends of each pipe
size and wall thickness at each fabrication site shall be examined 100 % for each production series
where bending parameters have been reset. Provided no defects are revealed during this
examination the extent of examination may be reduced to the indicated percentage. Sub-contractors
to the main sites are in this respect considered separate sites.

4) If defect indications are revealed, the NDT extent shall be increased to 100 % until the reasons for
the defect indications are concluded and necessary corrections in the forming process are made.

3.8 Production Testing

All materials, except 22% Cr and 25% Cr Duplex Steel:

One set of mechanical production tests shall be carried out for each qualified bending procedure on
preferably a pipe with the greatest diameter and wall thickness at the start of the manufacture at each
fabrication site. Sub-contractors to the main sites are in this respect considered separate sites.

Additional testing may be specified dependant on type of materials, dimensions, quantities to be bent
and the results of the qualification testing.

22% Cr and 25% Cr Duplex Steel:

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 6 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

One set of mechanical production test shall be carried out on each pipe size (OD) and wall thickness at
each bending site. Sub-contractors to the main sites are in this respect considered separate sites.

The type of tests and acceptance criteria for bends shall be as for qualification. For welded 22% Cr and
25% Cr Duplex SS pipes, material certificates shall be checked; if the lowest reported Charpy V single
value is below 100 Joule (standard specimen), impact testing shall be performed for this position after
bending to verify compliance with NORSOK M-601.

If heat treatment is carried out after bending, testing shall be carried out as specified in the respective
MDS, ESK and reference standard.

3.9 Certification

Cold bent pipes which have undergone a new heat treatment e.g. normalising, quenched and tempering
or solution annealing shall be subject to re-certification. The new testing including lot definition,
extent of testing, test location, acceptance criteria, etc. shall be in accordance with the MDS, ESK and
reference standard for fittings.

3.10 Dimensional Test

All components shall be subject to 100% dimensional check. The dimensions shall comply with the
applicable Piping Fabrication Specification,

4 Induction Bending

4.1 Wall Thickness

The design pressure of the relevant piping class shall be used for wall thickness calculations.

Minimum wall thickness at extrados shall be calculated from nominal wall thickness minus the
undertolerance.

4.2 Bending of Welded Pipe

The longitudinal weld of welded pipes shall be located in a zone ±40° from the bend neutral axis.

4.3 Post Bending Heat Treatment

When solution annealing heat treatment is required, the heat treatment manufacturer shall be qualified
according to Norsok M-650. This does not apply for heat treatment of 316(L) SS type of materials.

4.4 Bending Procedure

Induction bending shall be performed in accordance with a written and qualified procedure detailing:

• Material and applicable MDS

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 7 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

• Pipe surface condition

• Diameter
• Bend radius
• Wall thickness after bending (min. / max.)
• Bending equipment
• Bending speed
• Bending temperature
• Cooling technique
• Any post bending heat treatment
• Inspection and NDT of bends, including acceptance criteria

4.5 Surface conditions

Pipes selected for induction bending shall be free from rust, dents or surface contaminants which may
have a detrimental affect the final product. At no time, prior to or during bending, shall the pipe
contact low melting temperature materials such as zinc, aluminium, copper etc.

4.6 Qualification

Qualification shall be performed for each combination of the following essential variables:

Material : Each quality and grade / UNS number

Diameter [D] : +100 % - -50 %
Wall Thickness [t] : +25 % - -50 %
Bend Radius : One radius qualifies all larger radii
Bending Temperature : ± 25 °C, related to position on pipe
Bending Speed : ± 20 %
Cooling Technique : Any change
Post Bending Heat Treatment : Any change

Specimens for destructive testing shall be sampled from both intrados and extrados in the bending
zone and in the transition zone. For welded pipes, both the base material and the weldment shall be
tested.

The material properties of the qualification bend shall be verified by testing after bending. The type of
test and acceptance criteria shall be as for the applicable MDS and reference standard. For bends
intended for sour service the requirements of ISO 15156 / NACE MR0175 shall be fulfilled.
A sketch for testing shall be made including dimensions and type of test samples. The sketch shall
indicate start point of heating and end point of heating

• The qualification bend shall be subjected to 100 % visual examination and 100 % MT or PT as
applicable. For welded pipe the weld area shall be 100 % radiographed after bending. The use of
UT as a substitute for RT may be acceptable for large wall thicknesses. NDT procedures and
acceptance criteria shall be according to the reference standards for pipes and fittings as listed in
the MDS.

The out-of-roundness and wall thickness of the qualification bend shall be checked before and after
bending. The requirements of the design code shall be met.

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 8 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

4.7 Non Destructive Testing for production

The following NDT shall be performed on all induction bent pipe:

Visual Examination : 100 % externally and internally

NDT : As given in the relevant MDS, ESK and
reference standard for fittings. As a minimum,
2 % of the production bends shall be 100%
tested by PT or MT.

NDT procedures and acceptance criteria shall be according to the reference standards for pipes and
fittings as listed in the MDS.

4.8 Certification

All induction bent pipes shall be re-certified. The new testing including lot definition, extent of testing,
test location, acceptance criteria, etc. shall be in accordance with the relevant MDS, ESK and the
reference standard for fittings. The certificate documenting all specified tests shall be according to EN
10204, type 3.1.

4.9 Dimensional Test

All components shall be subject to 100% dimensional check. The dimensions shall comply with the
applicable Piping Fabrication Specification,

5 Flaring

5.1 Design requirements

Production of flared laps at pipe ends can only be performed for pressure rating up to Class 150 when
shown on the piping class data sheet, but limited to maximum 8” diameter. For flaring of SS type
316(L), only non-flammable utility services are allowed.

All requirements of ASME B31.3 shall be fulfilled.

Requirements in paragraph 306.4.2 are highlighted:

ASME B31.3, para. 306.4.2. Flared Laps

a) The outside diameter of the lap shall be in accordance with dimension of an ASME B16.9 lap-joint
stub end.(See deviation below)
b) The radius of fillet of the flared lap shall not exceed 3mm, and the backing flange shall meet
requirements of para. 308.2.5.
c) The lap thickness, measured at any point, shall be at least 95% of the minimum pipe wall thickness
T multiplied by the ratio of the pipe outside radius to the radius at which the lap thickness is
measured.
d) Pressure design shall be qualified as required by para. 304.7.2.

For qualification of pressure design, burst testing is the preferred method.

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 9 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

Deviation to ASME B31.3, para. 306.4.2.

Outside diameter of flared lap shall be in accordance with table 5-1.

5.2 Post flaring heat treatment

When solution annealing heat treatment is required, the heat treatment manufacturer shall be qualified
according to Norsok M-650. This does not apply for heat treatment of 316(L) SS type of materials

5.3 Flaring Procedure

All flaring shall be performed in accordance with a written and qualified procedure detailing:

• Material and applicable MDS

• Diameter
• Wall thickness
• Type of forming equipment
• Relevant forming parameters
• Inspection and NDT of flared laps including acceptance criteria
• Any post flaring heat treatment
• Production testing

5.4 Qualifications

Qualification shall be performed for each combination of the following essential variables:

Material : Each quality and grade / UNS number

Type of Pipe : Welded pipe qualifies seamless, but not vice versa
Diameter [D] : + 50 % - -50 %
Wall Thickness [t] : + 10 % - -25 %
Outside diameter ratio of : +10% - - No limit
flared lap and pipe [Dfl/D]
Heat Treatment : Any change
Type of equipment : Any change

The rest ductility shall be checked by tensile testing. Small size tensile test specimens located
tangentially as close to the outer edge of the flare as possible shall be used. Minimum elongation shall
be 10%.

The qualification flare shall be subjected to 100 % visual examination and 100% PT. The acceptance
criterion is no cracking.

5.5 Non Destructive Testing for production

The NDT requirements for cold forming shall be as stated below. The same NDT groups as for M-601
are used. For PT the acceptance criteria shall be in accordance with ASME VIII, Div.1, Appendix 8.

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 10 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

NDT SERVICE PRESSURE STARTING PIPE EXTENT OF NDT

GROUP RATING [%]
Visual PT
1 Non-flammable PN 20 Flared laps 100 Spot1)
and non-toxic (# 150)
fluids only

Notes:
1) Spot means that 2 % of the number of the flared ends of each pipe size, wall thickness and type of
material at each fabrication site shall be examined 100 %. Sub-contractors to the main sites are in
this respect considered separate sites. The flared ends to be examined shall be uniformly
distributed throughout the manufacturing period and shall be representative of the production.

5.6 Production Testing

One production test shall be carried out for each qualified procedure on the largest pipe size and wall
thickness to be flared at the start of the manufacture at each fabrication site. Sub-contractors to the
main sites are in this respect considered separate sites.

Additional testing may be specified dependant on grade of materials, dimensions, quantities to be bent
and the results of the qualification testing.

Tests and acceptance criteria shall be as specified for qualification testing in sect. 5.3.

If heat treatment is carried out of flared laps, testing shall be carried out as specified in the respective
MDS and reference standard.

5.7 Certification

Flared pipes which have undergone a new heat treatment e.g. normalising, quenched and tempering, or
solution annealing shall be subject to re-certification. The new testing including lot definition, extent
of testing, test location, acceptance criteria, etc. shall be in accordance with the MDS, ESK and
reference standard for fittings.

5.8 Dimensional Test

All components shall be subject to 100% dimensional check. The dimensions shall comply with ASME B16.9
lap-joint stub end except outer diameter of flared collar.

Table 5-1: Outside diameter of flared lap.

Max./Min. dimension on Flared Collar
Pipe dim. Max. (mm) Min. (mm)
1” 51 46
1,5” 73 65
2” 92 82
3” 127 115
4” 157 144
6” 216 201

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Classification: Open Page 11 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

8” 270 254

6 Definitions
ESK Element Specification Key
HC Hydrocarbon
MDS Material Data Sheet
MT Magnetic Particle Testing
NDT Non Destructive Testing
PED Pressure Equipment Directive
PBHT Post Bending Heat Treatment
PT Penetrant Testing
RT Radiographic Testing
SS Stainless Steel
UT Ultrasonic Testing
WT Wall thickness

7 Modifications to previous version

Editorial and technical modifications have been performed in several sections of the document.

8 References
ASME VIII, Div.1 ASME Boiler and Pressure Vessel Code
ASME B31.3 Process Piping.
ASME B16.9 Factory-Made Wrought Buttwelding Fittings
ASTM B861/B862 Standard Specification for Titanium and Titanium Alloy
Seamless/Welded Pipe.
TR2000 (L-SP-200) Piping and Valve Material Specification.
EN 10204 Metallic products. Types of inspection documents
ISO 15156 / NACE MR0175 Petroleum and natural gas industries – Material for use in
H2S –containing environments in oil and gas production.
Norsok M-601 Welding and Inspection of Piping
Norsok M-650 Qualification of manufacturers for special materials.

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Classification: Open Page 12 of 13
 Statoil governing document
Requirements for bending and flaring of piping
Technical and professional requirements TR1969, Final Ver. 2, Valid from 2006-09-29

App A Limitations and special requirements for cold bent pipes.

1) MDS 2) LIMITATIONS AND/OR ADDITIONAL REQUIREMENTS
MATERIAL SERVICE
CMn steel type 235 C01 Utility Service and non- None
C02 sour HC-service
HC sour service Max. hardness 250 HV10. Post bending heat treatment (PBHT) may be required.
CMn-steel for LT service C11 All New heat treatment (normalising or quench and tempering) is required. The material shall be re-
certified in accordance with the requirements in the applicable MDS and reference standard after heat
treatment. The extent of testing, lot definition and acceptance criteria shall be as for the applicable
MDS and reference standard for fittings.
SS 316 S05 Utility Service and non- None
sour HC-service
HC sour service Max. hardness 22 HRC.
22 % Cr duplex SS and D22 Utility Service and non- Impact testing and hardness of weld and base material shall be included in the qualification of the
25 % Cr duplex SS D35 sour HC-service procedure. Test temperature and acceptance criteria shall be as per Norsok M-601 Table 1.
Solution annealing may be required. The material shall be re-certified in accordance with the
requirements in the applicable MDS and reference standard after heat treatment. The extent of testing
and lot definition shall be as for the applicable MDS and reference standard for fittings.
HC sour service Impact testing and hardness testing of weld and base material shall be included in the qualification of
the procedure. The impact test temperature and acceptance criteria shall be as per Norsok M-601,
Table 1. Max. hardness shall be 36 HRC for 22% Cr duplex SS with 30<PREN<40 (min. 1.5wt% Mo)
and ferrite level 35-65% giving a pH2S limit per ISO 15156 of 0.02 bar. Max. hardness shall be 36
HRC for 25% Cr duplex SS with 40<PREN<45 and ferrite level 35-65% giving a pH2S limit per ISO
15156 of 0.2 bar. If the sour service environment is more severe than the limitations given in ISO
15156 / NACE MR0175, additional testing is required. Solution annealing may be required. The
material shall be re-certified in accordance with the requirements in the applicable MDS, ESK and
reference standard after heat treatment. The extent of testing and lot definition shall be as for the
applicable MDS, ESK and reference standard for fittings.
SS 6Mo S51 All Max. hardness 35 HRC.
Titanium Gr. 2 T02 Utility Service and non- None.
sour HC-service
HC sour service Not accepted.
Note 1) Materials which are not listed in this table may be cold bent provided written acceptance from Company is obtained.
Note 2) Types 22% Cr and 25% Cr duplex SS in cold worked conditions shall for all services be restricted to a maximum hardness of 32 HRC if used in contact with cathodic
protection.

Validity area: Statoil Group/All locations/All value chains/On- and offshore

Classification: Open Page 13 of 13