PIPE COLD BENDING PROCEDURE - DAWCO

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PROCEDUREPIPE BENDING PROCEDUREPIPE COLD BENDINGPROCEDURERevision -262016-06-21AllCover PageInitial IssueRevise procedure titleApproved byName: Gordon CanningTitle: Corporate Quality Manager, Western CanadaSignature:Date: 2016-06-21GordonCanningDigitally signed by Gordon CanningDN: cn Gordon Canning, o CorporateQuality Manager, ou DCM,email gcanning@dcmgroup.ca, c CADate: 2014.12.11 13:17:08 -07'00'CSA 178.2 Level 3Gordon Canning2016.06.21 08:56:58-06'00'DCM-PR-AQ-107-ADCM-PR-AQ-107-APage 1 of 5Uncontrolled if printed.Confidential – Property of DCM GroupReproduction, recording and distribution, in whole or in part, in any form or by any means, is strictly prohibited without prior written authorization from DCM Group.Rev. 2.0 – 2016-06-21

PROCEDUREPIPE BENDING PROCEDURE1.0 Purpose1.1This work instruction provides the technical requirements for cold bending of small boreseamless and seam welded piping (3 inch nominal pipe size and under) and pipe embeds.It shall be considered as a supplemental work instruction to DCM-AQ-MA-02 QualityControl Manual (Latest Edition).1.2This procedure also provides the methods required for qualifying the bending equipmentused to bend carbon and stainless pipe to the requirements of this work instruction2.0 Definition2.1Cold Bending- The application of mechanical force used to shape or bend carbon orstainless steel shapes.3.0 Application3.1Any project requiring cold bending of carbon or stainless steel piping.4.0 Responsibility4.1The Corporate Quality Manager is responsible for development, issuance and maintenanceof the procedure.4.2The project Quality Control Supervisor is responsible for verifying qualification of bendingequipment, inspections and the monitoring of the bending operations through surveillanceconducted, and ensuring that the proper documentation completed and filed.4.3Quality personnel are responsible for examining, and monitoring pipe bending process toensure that the requirements of this procedure are being met.4.4The Superintendent or his designee shall be responsible for pipe bending operations whichshall comply with the requirements of this procedure.5.0 Methods (Cold Bending)5.1Cold bending of pipe shall be performed within the following specified material temperaturelimits:5.2For austenitic stainless steel - not higher than 176.6 C (350 F) nor lower than 4.5 C (40 F).5.3For carbon and galvanized steel - not higher than 537.7 C (1000 F) nor lower than 4.5 C(40 F).5.4Prior to bending, pipe shall be free of scale, dirt, oil, grease or other deleterious material.5.5Dies or benders shall be wiped clean prior to application of bending lubricant or bendingoperation.5.6After bending carbon steel piping and prior to bending stainless steel piping, the bendingshoes shall be cleaned by swabbing 10-30 minutes with 20-25% nitric acid heated to 48.8 C– 71.1 C (120 F - 160 F) and thoroughly rinsed with demineralized-quality water to removeacid.5.7All pipe bending shall be performed using qualified bending equipment.5.8Bending requirements for seam welded austenitic stainless steel pipe are as follows:DCM-PR-AQ-107-APage 2 of 5Uncontrolled if printed.Confidential – Property of DCM GroupReproduction, recording and distribution, in whole or in part, in any form or by any means, is strictly prohibited without prior written authorization from DCM Group.Rev. 2.0 – 2016-06-21

PROCEDUREPIPE BENDING PROCEDURE6.0 Bending requirements for Austenitic Stainless Steel Pipe6.1For single or multiple bends made in the same plane, the pipe shall be oriented so that,whenever possible, the seam is positioned along the neutral axis of the bend (top orbottom of a horizontal bend).6.2For multiple bends in more than one plane, bends shall be confined first to the neutralaxis, then to the inside bend radius, and then to the outside bend radius.6.3All stainless steel pipe, identified by the mill markings or material certifications as"welded," shall be visually examined to locate the weld seam6.4Pipe bends shall maintain a circular cross section.6.5Bends shall be smooth, free from cracks, surface defects, buckles, and wrinkles.6.6Production bends shall be checked for percent ovality whenever ovality visually appears tobe questionable, even though the bending machine has been satisfactorily qualified.6.7If any defects are found, the pipe bend shall be marked as scrap and discarded.7.0 Pipe Bending Equipment Qualification7.1Each pipe bending machine shall be qualified at the jobsite prior to production bending.7.2Qualification shall consist of performing test bends on each pipe size, material type, andschedule to demonstrate that the following pipe minimum wall and ovality requirementscan be met:7.3Each pipe to be tested shall be bent to a 90 bend ( 3 ) at the smallest bend radius forthe particular pipe size, type and schedule permitted by the applicable ContractSpecification.7.4Each pipe bend shall be sectioned in four (4) pieces in accordance with the Pipe BendingMachine Qualification Form (Figure 1).7.5Wall thickness and ovality shall be measured on each piece.7.8Minimum wall thickness after bending shall not be less than 87.5 % of the nominal wallthickness of the pipe being bent.7.9Ovality after bending shall not exceed 8%, as determined by ASME B31.3.7.10 All required measurements and calculations shall be documented on Figure 1. Once thebending machine has been found acceptable, further qualification is not required.7.11 Pipe bending machine qualification shall be witnessed and documented by the QCInspector on the document shown in Figure 1.7.12 Each qualified pipe bending machine shall have an attached document delineating thebend radius, type of material, and pipe schedule which can be formed by the applicablemachine, based on the machine qualification.7.13 Surface IrregularitiesPipe wall conditions, e.g. ovality, buckling, wrinkling, or flattening, due to machinemalfunction shall be cause for machine requalification prior to the continuance of anyproduction beyond the point of discovery.DCM-PR-AQ-107-APage 3 of 5Uncontrolled if printed.Confidential – Property of DCM GroupReproduction, recording and distribution, in whole or in part, in any form or by any means, is strictly prohibited without prior written authorization from DCM Group.Rev. 2.0 – 2016-06-21

PROCEDUREPIPE BENDING PROCEDURE8.0 Quality Assurance8.1Project Quality Control Supervisor and / or Quality Control Inspectors shall conductperiodic surveillance and audits to assure compliance with the contract, Codes and workprocedure requirements. Project Quality surveillance and audit shall be documented andadministratively controlled as described in DCM-AQ-MA-02.8.2Nonconforming items identified during construction shall be controlled and dispositioned inaccordance with Section 12 of DCM’s ASME Quality Control Manual (DCM-AQ-MA-02).8.3The QCS shall compile and maintain records are required by the procedure and DCM’sASME Quality Control Manual.9.0 ReferencesDCM-PR-AQ-107-A Applicable Contract Specifications ASME B31.3 / ASME B31.1 ASME Quality Control Manual (DCM-AQ-MA-02)Page 4 of 5Uncontrolled if printed.Confidential – Property of DCM GroupReproduction, recording and distribution, in whole or in part, in any form or by any means, is strictly prohibited without prior written authorization from DCM Group.Rev. 2.0 – 2016-06-21

PROCEDUREPIPE BENDING PROCEDUREFIGURE 1- PIPE BENDING MACHINE QUALIFICATION FORMDoes cut violate min wall?DCM-PR-AQ-107-APage 5 of 5Uncontrolled if printed.Confidential – Property of DCM GroupReproduction, recording and distribution, in whole or in part, in any form or by any means, is strictly prohibited without prior written authorization from DCM Group.Rev. 2.0 – 2016-06-21

7.0 Pipe Bending Equipment Qualification 7.1 Each pipe bending machine shall be qualified at the jobsite prior to production bending. 7.2 Qualification shall consist of performing test bends on each pipe size, material type, and schedule to demonstrate that the following pipe minimum wall and ovality requirements can be met:

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