Document No METHOD STATEMENT FOR Page 1 of 12

ESR00550-MS-01 COLD FIELD BENDING PROCEDURE

Rev. A

PROJECT: ENOC-EPCL
PROJECT NO.: ESR00550
REFINERY EXPANSION PIPELINE WORKS

METHOD STATEMENT
FOR
COLD FIELD BENDING PROCEDURE

DOCUMENT NO. ESR00550-MS-001

PREPARED BY:

REGIONAL QHSE MANAGER ______________________________

APPROVED BY:

PROJECT MANAGER ______________________________

REV SUBJECT OF THE REVIEWED BY AND AUTHORIZED BY AND

DATE
NO. AMENDMENT SIGNATURE SIGNATURE

A For Internal Review

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ESR00550-MS-01 COLD FIELD BENDING PROCEDURE
Rev. A

CONTENTS

SECTION

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCE DOCUMENTS

4.0 DEFINITIONS & ABBREVIATIONS

5.0 HEALTH, SAFETY AND ENVIRONMENT

6.0 TRAINING OF PERSONNEL

7.0 ROLES & RESPONSIBILITIES

8.0 EQUIPMENT AND MATERIALS

9.0 PROCEDURE

10.0 DOCUMENTATION

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ESR00550-MS-01 COLD FIELD BENDING PROCEDURE
Rev. A

1.0 PURPOSE

The Purpose of this Method Statement is to define the specific tasks to be performed
by Overseas AST LLC during cold field bending operations on the Installation of 24-
Inch Pipeline ESR00550-Refinery Expansion Pipeline Works.

2.0 SCOPE
This procedure is intended to provide a detailed description of shop cold bending
operations of 24” pipes which is passing through DWC corridor under the EPCL
The scope of this Methos
REFINERYStatement
EXPANSION is–to provide
PIPELINE a detailed
WORKS field
(ESR00550 description of cold
- NI/3367) project.
bending operations on the Installation of 24-Inch Pipeline ESR00550-Refinery
Expansion Pipeline Works. and to ensure that the work is performed in a safe,
professional and controlled manner by competent trained staff.
.
add PFI ES-24 - Pipe Bending Methods, Tolerances,
3.0 REFERENCE DOCUMENTS Process and Material Requirements

3.1 Contract Scope of Work

3.2 Project Specification

ASME B31.3
3.3 ASME B31.8 – Gas Transmission and Distribution Piping System

3.4 Project Health, Safety and Environmental Plan and Procedures

3.5 EES-L-10-Fabrication Steel & and Tubing Assemblies

3.6 Project Quality Plan and Procedures

3.7 Pipeline Alignment Drawings Drawing Number

4.0 DEFINITIONS

4.1 COMPANY ENOC -EPCL

4.2 ROW Right of Way

4.3 PTW Permit to Work

4.4 PPE Personnel Protective Equipment

4.5 SWL Safe working Load

4.6 IP Intersection Point

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5.0 HEALTH, SAFETY AND ENVIRONMENT Only minimum information

required

5.1 Induction

Prior to commencing work all personnel shall have attended the Project HSE Induction
Course conducted by the over Seas HSE Department.

5.2 PPE

All personnel involved in cold field bending activities shall comply with the Project
requirements for PPE. Where appropriate, training shall be given in the use of PPE.

The PPE requirements on site during cold field bending activities shall be:

 Work Boots with toe protectors

 Safety Helmet
 Eye Protection with side shields
 Coveralls
 Labourer’s Gloves

Personnel shall sign for items of PPE issued to them and the Supervisor shall ensure
daily that his crew is using the required PPE and that damaged or defective PPE is
replaced or repaired.

5.3 Operating Plant and Equipment

The Bending Supervisor shall inspect all equipment for damage and/or deficiencies
prior to the commencement of work each day and surveillance shall be maintained on
equipment to check if the equipment has sustained any damage during the course of
the working day. Defective items, that affect the safe operation of the piece of
equipment, shall be immediately taken out of service until repaired or replaced. Other
deficiencies shall be rectified as soon as possible.

Plant operators shall complete a Daily Plant & Equipment Checklist for the item of
plant they operate and shall report all deficiencies to the Supervisor who will arrange
the Plant Department to rectify the deficiencies.

 Only competent, licensed operators shall be permitted to drive and operate

sidebooms and cranes.
 Competent, experienced riggers under supervision of the Supervisor will undertake
any rigging work required when handling line pipe during cold field bending
operations.
 Banksmen shall direct the movement of all equipment around the site and shall
direct crane operator during lifting operations.

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5.4 Risk Assessment

Prior to the commencement of cold field bending activities, a risk assessment shall be
conducted jointly by the Construction Department and the HSE Department to ensure
that all hazards and risks are identified and the required mitigation measures are in
place, and remain fully implemented during operations.

5.5 Toolbox Talks

Prior to the commencement of cold field bending activities, the Supervisor with
support from the AST HSE Advisor shall conduct a pre-start toolbox talk with all the
crew present. The Supervisor shall explain the method of cold field bending, focusing
on the hazards and risks involved in the activity and the mitigation measures that shall
be taken as detailed in the Risk Assessment.

Regular Toolbox talks shall be conducted in order to prevent complacency within the
crew. Toolbox talks shall be documented and the records maintained by the HSE
department.

Should any new personnel join the bending crew during the duration of cold field
bending activities the Supervisor conduct a Pre-start toolbox talk for the new person/s
prior to the person/s starting work.

5.6 Environment

Dust control measures shall be implemented on sections of the ROW where dust will
be generated by the movement of trucks and equipment along the ROW.

The bending crew shall collect up all rubbish generated by bending activities and
dispose of rubbish in an approved waste disposal location.
Please Keep it short
6.0 TRAINING OF PERSONNEL

6.1 Safety Training

All personnel involved in cold field bending activities shall have received the
appropriate training applicable to their job designation.

Further training will be given as required and when the need additional training is
identified during the risk assessment process.

6.2 Trade Training

All personnel involved in cold field bending activities shall be assessed for
competency and if they have the required trade skills and experience required by their
job function.

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Competency assessment shall be made by verbally testing the person, checking trade
certificates (where applicable), and field evaluation (where applicable).

Please Keep it short

7.0 ROLES AND RESPONSIBILITIES

7.1 Construction Manager

Responsible to the Project Manager for:

 Ensuring that all lifting gear to be used is certified by an approved Third-

Party Authority.
 Ensuring that lifting gear and equipment is maintained and stored correctly.

7.2 Crew Supervisor

Responsible to the Construction Manager for:

 Implementing this construction execution procedure and other procedures

affecting pipe cold field bending.
 Participating in the risks assessment for cold field bending activities.
 Ensuring that adequate and competent or appropriately trained personnel
are available to perform the work.
 Supervising all pipe bending crew personnel.
 Verifying their training and competency levels.
 Ensuring plant and equipment is inspected and maintained in good order.
 Ensuring all cold field bending activities are carried out safely and under
the correct conditions.

7.3 QC Inspector

Responsible to the Senior QA/QC Engineer for:

Witnessing, inspecting and documenting bending procedure.

The surveillance inspection of cold field bending activities in accordance
with the Inspection and Test Plan.
7.4 HSE Advisor

Responsible to the Senior HSE Advisor for:

 Participating in the risk assessment for cold field bending activities.

 Ensuring that cold field bending activities are performed in a safe manner
in accordance with Project HSE procedures.
7.5 Crew
Responsible to the Supervisor for:
 Performing their work in a safe manner at all times.
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 Following the requirements of the risk assessment and this construction

execution procedure.
 Informing their Supervisor of any health, safety, environmental or quality
concerns.

8.0 EQUIPMENT AND MATERIALS Mention Equipment details, Capacity, Model

No, General arrangement drawing etc.

All plant and equipment, required for lifting

3 rollersoperations, shall
should be covered withbe tested
rubber sheet and approved
or other suitable materials
by an independent third-party authority prior to use on the Project. The Plant
Department shall maintain the load test certificates and a copy of the certificate
retained on site by the plant or machine operator.

The S.W.L. of all lifting equipment will be marked clearly on the equipment. All lifting
equipment should be securely stored and clearly identified and tagged to show
limitations of use and the date re-certification is required.

Cranes and sidebooms shall be of suitable capacity to handle the pipes and shall be
operated by approved personnel.

All bending machines shall be equipped with the necessary bending shoes to match
the external pipe diameter.

Bending shoes shall be covered with suitable material to avoid damage to the pipe
external 3LPE coating.

Hydraulically controlled internal mandrels are to be used to prevent buckling of the

pipe during bending operations.

9.0 PROCEDURE
9.1 General

Changes of the vertical and horizontal alignment of the pipeline, made necessary
by the actual condition and contour of the ground, shall be provided for, where
possible, by cold field bends.

Minimum cold field bend radius shall be equivalent to 18 times pipe diameters as
specified in ANSI/ASME B31.4. use parameters based
on ASME B31.3
Induction bends shall be provided where bends of smaller radius are required or
where such bends are specifically shown in approved alignment drawings.

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A bending procedure shall be performed to establish the minimum bend radius that
can be achieved on the wall thickness pipe using the AST bending machine and
equipment.

The procedure qualification bends shall meet the following criteria:

 The minimum acceptable cold field bend radius shall be equivalent to 18

pipe diameters.
This pipe is coated with 3.5mm thk 3LPE, please
check UT gauge suitability. Provide thickness
 Each pipe will have the gauge
walldetails
thickness checked, by ultrasonic,
at
predetermined points along the length of the pipe prior to bending. On
completion of bending the wall thickness shall be rechecked at the same
points to determine that any reduction in wall thickness does not exceed the
maximum under thickness tolerance specified in the pipe data sheets.

 The
Flattening of a bend, the difference between
maximum and minimum diameters shall be checked at predetermined
maximum and minimum diameters at any cross
section, shall not exceed 8% of nominal outside along the length of the pipe prior to bending. On completion of
locations
bending
diameter for internal pressure and 3% the diameters shall be rechecked at the same points. The
for external
pressure.
Removal of metal shall not be used to achieve between the maximum and minimum diameters of the completed
difference
these requirements. bend shall not exceed 2.5% of the nominal diameter.

 The completed bend shall be visually inspected and shall have a gauging
plate of 95% of the nominal internal diameter pulled through the pipe, to
ensure the pipe inside diameter is within the specification.

 The completed bend shall have a smooth contour and be free of

mechanical damage, cracks, wrinkles or buckles.

 No damage to external pipe coating (minor scuffing is acceptable) or

damage to the pipe bevel ends.

 The completed bend shall be holiday tested at the specified voltage to

check for external coating damage.

The bend data for each procedure bend shall be documented and shall form the
criteria for all the cold field bending to be performed on the Project.

9.2 Production Bend Requirements

Why 1.5m ?
All the pipe cold bends shall be according to the following requirements:
The minimum tangent length at each end of the bend shall be 1.5 m.

The radius of the cold bend shall be not less than 18 times the nominal pipe
diameter.

The longitudinal axis of the pipe shall not be deflected more that 1.5 degrees, in a
length along the pipe axis, equal to the pipe diameter.
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All completed bends shall be tested for ovality with a gauging plate consisting of
two aluminium discs rigidly connected at a distance of 750mm apart and having a
diameter not less than 95 % of the pipeline nominal internal diameter.

There shall be no significant coating damage (minor scuffing is acceptable) or

bevel damage evident on the completed bend.

The pipe end caps shall be reinstalled after the bending is completed.

The bend type (Sag bend, over bend, side bend or combination bend) and the
bend angle shall be clearly written on the outside of the pipe, using indelible
marker.

9.3 Bending Methodology

The bending operation shall be performed in accordance with the following

methodology:

The Bending Foreman shall systematically measure the length of each pipe and mark
the centreline of the pipe for subsequent slinging, transfer the pipe data (pipe number,
heat number and pipe length) to the end of the pipe, if not already done.

The degree of bends required shall be determined in the field by the Surveyor from
stripped ground levels, special crossing/ pipeline profile drawings.

The Surveyor will record the length, pipe number, heat number and angle required of
each strung pipe to be bent on the bending schedule.

Coating damage Pipes shall be visually inspected for coating and pipe damage/defects prior to
should be
referred to AST bending. Bending machine elements (shoes and dies) shall be checked to ensure
they are clean and free from any material that could damage the pipe, external
coating and internal lining.

The pipe shall be lifted, using a specialised belt and positioned on the stiff back end of
bending machine.

Hydraulically controlled mandrels are fitted internally at the bend location and are
used to prevent buckling of the pipe during bending procedure.

One end of pipe is lowered on to the roller and the pipe is moved halfway into the
machine then the mandrel will be loaded and set to the desired bend position.
The cable hook is then attached to the stiffback end of the pipe.

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The winch cable is slowly tensioned until the pipe is properly located for the first
bending operation and the stiffback is then raised.

The pin-up shoe is raised until the pipe touches the lowest point of the curvature of
the die.

The distance from the front of the die to the top of the pipe and the distance from the
rear of the die to the top of the pipe should be equal.

The bending gauge is marked at this setting as the reference starting point for each
increment of the bend for the size of pipe.

The pipe is marked with its centre point (length) and the pipe is lowered on to the
roller using the sideboom & lifting belt and the winch cable is unwound for
"freewheeling". The stiffback is then raised up to reference mark on the bending
gauge scale.

Then the pipe shoe is raised to the bending limit of the pipe or until the hydraulic
pressure gauge reads maximum at pressure.

The bending cycle is then repeated until the required degree of bend is achieved.

The step length shall be marked on the pipe and the required pull per step length shall
be made and measured by bending machine’s measuring rod.

After pipe is bent, but while still in the machine, the total amount of bend is measured
by using a clinometer or electronic true bend device.

Cold bending of ferritic materials shall be done at a temperature below the transformation range.

If lubrication or cooling liquids used, it must be compactable to use over 3LPE coating.

Attach Data Sheet & MSDS for the same

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10.0 Bending Procedure

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Include section for inspection & Testing

11.0 DOCUMENTATION

The Bending Foreman shall complete a Bending Report for all cold field bends and the
report shall be submitted to the AST QC Department at the end of each day’s work.
The AST QC Inspector shall verify the recorded data.

Coating damage should be referred to AST

Attach related formats, Calibration register

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