CLIENT :

PROJECT :

BEND GRADE : AS PER ANNEXURE A OF THIS QAP.

P.O. NUMBER : SHALL ADVISE

BEND SIZE AS PER ANNEXURE A OF THIS QAP.

:

TECHNICAL SPECIFICATION HOT INDUCTION BENDS AS PER CUSTOMER SPECIFICATION

:
Revision Record
Rev. No. Description Date Prepared By Reviewed By Approved By
Welspun Client/TPI

00 For Client Approval

01 For Final Client Approval

(A) SCOPE : Manufacturing of Long Radius hot pulled Induction Bends as per customer Specification :
1.0 Material Client Spec Each pipe Hot Induction Bends Shall be fabricated from Test certificates R R
Carbon Steel Line Pipes as per API 5L &
Client Specification
2.0 Inspection of Bare ----- Each Pipe As per customer specification & MTC Pipe Inspection report H R
Pipes Receiving Report shall be reviewed.
 The longitudinal weld seam of pipes used for
3.0 Weld Position Cust. Each Pipe ---- H R
bending shall be placed at the neutral axis
With a maximum offset of 10 deg from the
neutral axis of the bend.
4.0 Forming Of Bends H W

- Temperature Standard Procedure Each Bend Temp. Range :- 850° To 1050°C (±25º PBM Parameter
Shall be freezed after MPQT) Bend Forming Report
Temperature Shall be Selected in such a way
so that Mechanical & Metallurgical properties
are Maintained after bend forming operation.
- Speed Standard Procedure Each Bend 25 ± 15 mm /Min. (To be freezed ± 25 mm
after Test bend results)
- Cooling Standard Procedure Each Bend Instant cooling with air & water jet distributed
uniformly across the circumference to heated
annular Zone.
- Radius Fixing …………….. Each Bend ± 1 % of Bending Nominal Radius
- Pyrometer Cust. Spec.4.5 Each BendUsing an Temp. Against Speed Record Chart
Setting optical pyrometer
and temperature
chart recorder.
…………… ……..
4.1 Post Bending Heat ---------------------- Not Required. Bends Are Fabricated Under NA NA
Treatment / Stress Controlled Process Parameters. The
Relieving Required Mechanical & Chemical Properties
are achieved during bending process.
The gauge shall consist of Two Gauging
5.0 Pig Test ……….. Each Bend Dimensional H W
Plates. Having A Diameter Equal to 90% of
Inspection Report
the Nominal Internal Diameter of the Pipe,
Connected Rigidly Together at a Distance
Equal to 500 mm.

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 NON DESTRUCTIVE TEST

6.0

6.1 Manual Ultrasonic Cust. Spec. Each Bend both Full Circumference of both ends shall be MUT Report H
W
Testing ( Bevel Ends ) ends of Bevel Manual Ultrasonically Tested for Laminations
surface Over a Length of 50mm. Laminar
UP TO 50 mm max.
imperfections shall not exceed the limits
given in the respective clauses of EN 10208-
2 and Specification for Main Line Pipe,
Document No
6.2 Manual Ultrasonic Cust. Spec. Each bend, All seam welds of bend manufactured from MUT Report H RW
Testing (100% Weld LSAW pipes shall be 100% MUT Tested.
100 % weld length
seam
Acceptance criteria as per API 5L & EN
10208-2 and Specification for Main Line
Pipe, Document No. shall apply.
Acceptance criteria as per accordance with
6.3 Magnetic Particle Cust. Spec. Each bend MPI Report H W
ISO 13665 & client spec.
Inspection
(Both transition zones
and the arc of the bend)

Residual Magnetism shall not exceed 2 MT.

6.4 Residual Magnetism Cust. Spec. Each bend MPI Report H W

7.0 FINAL DIMENSIONAL INSPECTION

7.1 Bend Angle Cust Spec Each Bend ± 1˚ of The Specified Angle H 10 % RW

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 - Wall Thickness
7.2 Cust Spec Each Bend 10% thinning shall be permitted on the Dimensional H 10 % RW
(Wall thickness shall be
Thickness Check At mother pipe. Inspection Report
measured at the
At Min Interval Of
extrados and the
300mm Along The
intrados of the bend
Length of Bend

7.3 - Out Of Cust Spec Each Bend 2.0 % of Nominal outside diameter. Dimensional H 10 % RW
Roundness At Body More than 100 mm from bend end. Inspection Report
…… At Ends Over a As per Mother pipe Spec
Length of 100 mm
7.4 Bend Radius Cust Spec Each Bend ±1% of The Nominal Bend Radius Dimensional H 10 % RW
Inspection Report

7.5 Off Plane (Plane Of Cust Spec Cl 5.2.2 Each Bend As per client spec 5.2.2 H 10% RW
Bend)
The minimum length shall be 1D.
7.6 Tangent Length Cust Spec. Cl. 4.6 Each Bend at Both Dimensional H 10% RW
Ends Inspection Report
8.0 End Preparation API 5L Each Bend Bevel Angle - 30˚ (+ 5˚, - 0˚) Dimensional H 10% RW
Root Face - 1.6 mm (± 0.8 mm) Inspection Report
Squareness - 1.6 mm Max
9.0 WORKMANSHIP
As per Client Spec. 5.2.2
9.1 Bend Irregularity Cust Spec 5.2.2 If any H M
9.2 Inside Weld Bead Standard Procedure Each Bend Weld Material Shall Be Ground Flush Up to H M
Grinding 100 mm Minimum from Inside at Both Ends.
9.3 End Protector Cust Spec Cl-6.1 Each Bend Bend Shall Be Suitably Protected To Avoid H M
Any Damage During Transit By Means Of
Metallic Bevel Protectors.

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9.5 Marking Cust Spec Each Bend On The Marking As Per Client Specification H M
(150 mm From The End Inside Surface At
With Letter Size 30 mm One End

M
Bend number shall be Cust Spec ………… The height of the figures shall be in the H
hard stamped on one range from 5 mm to 7 mm with a minimum
bevel of the bend, using impression of 0.2 mm. Only Bend No. shall
round steel stamps. be hard stamped.
Certificate
9.6 Release documents Standard Procedure Final Acceptance Release Note/ Inspection Certificate & H H
Material test certificate
9.7 Documentation / Cust Spec & All Documentation As Per Client Certificate H R
Certification StandardProcedure Specification
………….
9.8 Packing …… NA NA
B.0 Manufacturing Procedure Qualification Test(Proto Type Bends)- one finished pipeline bend per wall pressure class, preferably 45° shall be
tested
B.1 Pig Test Test Bend As Per Cl. 5.0 Of This QAP. Visual &Dim. Report H H
B.2 Non-Destructive Testing Test Bend As Per Cl. 6.0 Of This QAP Test Report H H
B.3 Visual & Dimension Test Bend As Per Cl. 7.0 & 9.0 Of This QAP Visual & Dim.Report H RW 10%
Acceptance Shall Be As Per CLIENT SPEC. &
B.4 Tensile test (base) Cust Spec Test Bend Mother Pipe MTC. Test Report H H
transverse one sample
each from following
location.bend arc, transition
zone and tangent section.

Acceptance Shall Be As Per CLIENT SPEC.

B.5 Tensile Test (Weld) Cust Spec Test Bend Test Report H H
& Mother Pipe MTC.
One Face And One Root Face Guided Bend. Test Report
B.6 Guided Bend Test Cust Spec Test Bend H H

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 Hardness readings shall not exceed 300 HV
B.7 Through Thickness Cust Spec 5.3.5.4 Test Bend H H
(Vickers Hardness) 10 at any point, including Test Report
Hardness Test
Test force of 98.07 N. The HAZ. The average value of the three
Base, Weld, HAZ, FL, hardness readings at each location of a
production bend shall not vary by more than
the equivalent of 80 hv 10 hardness points
from the average value measured in the
same location of the test bend
B.8 Surface hardness Test Cust Spec cl. 5.3.5.4 Test Bend Acceptance as per Mother pipe spec. & Test Report H H
Two circumferential MTC.
locations in the arc and
across one
circumferential location
in each tangent.
Charpy V-Notch Impact Cust Spec Cl 5.3.5.3 Test Bend Test Temperature to be – 20°C Test Report H H
Test Acceptance Shall Be As Per Acceptance as
per Mother pipe MTC.
Transverse
Acceptance as per Mother pipe MTC. (Full
B.9 direction. Size Specimen/Sub Size Specimen Shall By
(Base, Weld Centre Line, used)The minimum average shear area 50
Fusion Line, FL+2,FL+5) % and all individual shear area.40 %
B.10 Metallographic
Cust Spec Cl 5.3.5.6 Test Bend Acceptance as per Mother pipe spec. & Test Report H H
examination Test Bend
Magnification of not MTC.
arc, transition and
less than 100 ×.
tangent materials
B.11 Hydro Test (90% Of Cust Spec Cl 5.6 Only Test Bend & Acceptance as per Mother pipe spec. & Test Report H H
SMYS) 5% of theproduction MTC.
bends.
Legend: H – Hold, M – Monitor, R – Review, Rw – Random Witness (10%), Tpi – Third Party Inspection, W – Witness, P- Proceed, D – Out Side Diameter
Annexure A
Sr. No. Diameter Radius Required wall Angle Quantity Sr. No. Diameter Radius Required wall Angle Quantity
thickness category thickness category
equivalent equivalent
1 56" 5D 18.0 11° 1 16 56" 5D 21.5 45° 4
2 56" 5D 18.0 18.75° 1 17 56" 5D 25.5 17.5° 1
3 56" 5D 18.0 20.79° 1 18 56" 5D 25.5 20.65° 1
4 56" 5D 18.0 20° 1 19 56" 5D 25.5 20° 1
5 56" 5D 18.0 22.5° 1 20 56" 5D 25.5 22.5° 6

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6 56" 5D 18.0 24.57° 1 21 56" 5D 25.5 25.93° 1
7 56" 5D 18.0 27.35° 1 22 56" 5D 25.5 28.34° 1
8 56" 5D 18.0 27.62° 1 23 56" 5D 25.5 30° 27
9 56" 5D 18.0 30° 26 24 56" 5D 25.5 32.5° 1
10 56" 5D 18.0 37.5° 2 25 56" 5D 25.5 35° 2
11 56" 5D 18.0 41.5° 1 26 56" 5D 25.5 45° 23
12 56" 5D 18.0 45° 11 27 56" 5D 32.0 35° 2
13 56" 5D 21.5 25.76° 1 28 56" 5D 32.0 45° 2
14 56" 5D 21.5 30° 1 29 56" 5D 21.5 19.82° 1
15 56" 5D 21.5 34.2° 1

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