Hdpe Field

Sociedad Min era Cerro Cerro Verde Verde S.A.A.

Prima rim ary Sulfide ulf ide Proj Proje ect Project No. PSP108

Field Fa Fabric br ica ation ti on and Ins Installatio tallation n o f HDP HDPE Pi p i n g

Clien t Name: Project Name: Name: Proj ect Numb er:

Socied ad Minera Cerro Verde S.A.A. Primary Sulfide Project PSP108 PSP108

Specif icati on C-CS-50-00 C-CS-50-005 5 Page 1 of 14 Rev. C

FLUOR Mining & Minerals

FIELD FABRICATION AND INSTALLATION OF HDPE PIPING

This document has been revised as indicated below. Changes after revision 0 are identified by vertical bars at the right side of the page, with additions being underlined. Please replace all pages of this specification and destroy the superceded copies. English is the prevailing language of this document. Rev No. C

Originator (name/initials) Yiu-Tak Tse

Rev Date 14Mar05

Revision Revision Descripti Descripti on Issued for Approval






This document has been revised as indicated below. Changes after revision 0 are identified by vertical bars at the right side of the page, with additions being underlined. Please replace all pages of this specification and destroy the superceded copies. English is the prevailing language of this document. Rev No. C

Originator (name/initials) Yiu-Tak Tse

Rev Date 14Mar05

Revision Revision Descripti Descripti on Issued for Approval





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING Table of Contents 1.

GENERAL ................... ............................ .................. ................... ................... .................. ................... ................... .................. ................... ................... ................. ................ ................. ................... ............3 ..3

1.1

Summary ................................. ................ ................. ................. ................. ................. ................................. ................ ................. ....................... ........... 3

1.2

References ................... ............................ ................... ................... .................. ................... ................... .................. ................... ................... ................... ................. ................ .................. .................. ..........3 .3

1.3

Terminology...................................................................................................................................................4

1.4

Quality Assurance .................. ............................ ................... .................. ................... ................... ................... ................... .................. ................... ................. ................ .................. ..................5 .........5

1.5

Site Conditions .................. ........................... ................... ................... .................. ................... ................... .................. ................... ................... .................. ................ ................ ................... ...............6 .....6

2.

MATERIAL S RECEIVING, RECEIVING, INSPECTION, INSPECTION, AND STORAGE....................... STORAGE................................. ................... .................. ................... ................... ...........6 ..6

2.1

Materials Receiving and Inspection................... Inspection............................. ................... ................... ................... ................... ................... ................... ................. ................ ..................6 .........6

2.2

Pre- Installation Storage & Exposure to Weather ................... ............................ .................. ................... ................... ................... ................... ................. ..............7 ......7

3.

FUSION BONDING QUAL IFICATION REQUIREMENTS REQUIREMENTS ................... ............................ ................... ................... .................. ................... ...................8 .........8

3.1

General ................................. ................ ................. ................. ................. ................................. ................ ................. ................. ....................... .............. 8

3.2

Bonding Procedure Specification (BPS) Requirements .................. ........................... ................... ................... .................. ................... ................... ...............9 ......9

3.3

Bonding Procedure Qualification Record (BPQR) Requirements.............. Requi rements....................... ................... ................... .................. .................. ..............9 .....9

4.

EXECUTION EXECUTION OF FIELD FUSION BONDING AND INSTALL ATION......... ATION ................... ................... ................... ................... ...................10 ..........10

4.1

Pipe and Fitting Field Fabrication ................... ............................ .................. ................... ................... .................. ................... ................... .................. ................... ...................10 .........10

4.2

Field Testing, NDE, and Inspection.......................... Inspection................................... ................... ................... ................... ................... .................. ................... ................. .................11 ..........11

4.3

Bonding

4.4

Field

5.

INSPECTION, NDE AND TESTING REQUIREMENTS FOR HDPE FUSION JOINTS.............................12

5.1

General Inspection Requirements................ Requirements......................... ................... ................... .................. ................... ................... .................. ................... ................. ................. .............12 ...12

Repair............................................................................................................................................11

Installation...........................................................................................................................................11





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING 1.

GENERAL 1.1

Summary A.

Scope of Specification This specification stipulates the criteria for fusion bonding, inspection, examination, qualification, testing, and installation of High High Density Polyethylene (HDPE) (HDPE) in pressure applications. Pipe and fittings bonded per this specification shall satisfy the requirements for ASME B31.3 for pressure piping applications. 1.

B.

Any deviation from this specification requires written written authorization from the Buyer. Buyer.

2.

This specification is applicable to both shop and field fabrications.

3.

The fusion procedures and recommendations are based on best industry practice and past project experience. Manufacturer recommendations shall also be incorporated into fusion procedures. The Buyer shall resolve any conflicts between this specification and Manufacturer recommendations.

Related Specifications The following specifications describe items of related work: 1.

C-DC-10-002

Site Conditions

2.

C-CS-10-004

Sanitary Sewer

3.

C-CS-10-005

Storm Sewer and Culvert

4.

C-CS-10-007

Watermains

5.

C-CS-50-013

Ultrasonic-TOFD Inspection for HDPE Pipe

Clien t Name: Project Name: Proj ect Numb er:

Socied ad Minera Cerro Verde S.A.A. Primary Sulfide Project PSP108

Specif icati on C-CS-50-005 Page 4 of 14 Rev. C



D.

2.

D2122

Standard Test Method for Determining Dimensions of Thermoplastic Pipe and Fittings

3.

D2657

Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings

4.

D2683

Standard Specification for Socket-Type Polyethylene Fittings for Outside Diameter-Controlled Polyethylene Pipe and Tubing

5.

D2774

Standard Practice for Underground Installation of Thermoplastic Pressure Piping

6.

D3261

Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing

7.

F412

Standard Terminology Relating to Plastic Piping Systems

8.

F714

Polyethylene (PE) Plastic Pipe (SDR-PR) based on Outside Diameter

9.

F905

Practice for Qualification of Polyethylene Saddle Fusion Joints

10.

F1056

Standard Specification for Socket Fusion Tools for Use in Socket Fusion Joining Polyethylene Pipe or Tubing and Fittings

11.

F1668

Standard Guide for Construction Procedures for Buried Plastic Pipe

12.

F1804

Standard Practice for Determining Allowable Tensile Load for Polyethylene (PE) Gas Pipe During Pull-In Installation

13.

F2164

Field Leak Testing of Polyethylene (PE) Pressure Piping Systems Using Hydrostatic Pressure

AWS (American Welding Society) G1.10M

Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated Tool Butt Thermoplastic Welds





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING E.

Butt-weld Fusion Bonding – A joint in which the prepared ends of the HDPE pipe are heated against a hot plate to the desired temperature, which allows for the ends to be fused together via application of external pressure

F.

Buyer – Refer to the Owner of the project or Owner’s representative

G.

Contractor – Refer to any company or persons performing fusion welds or pipe installation, including sub-contractors

H.

Field Fabricate – Piping fabrication completed at the jobsite, including either a field shop or at the installation location

I.

HDPE – High Density Polyethylene

J.

Insert Fusion Bonding – See Socket Fusion Bonding

K.

Inspection Contractor – Any company or persons performing Ultrasonic- Time of Flight Diffraction (UT-TOFD) inspection of fusion welds, including sub-contractors

L.

Manufacturer – Unless otherwise noted, the company or organization that produces HDPE pipe that has been approved for use for this project

M.

Saddle Fusion Bonding – A joint in which a contoured heating plate is used to simultaneously heat the curve base of the saddle fitting and a corresponding area of the pipe surface to the required temperature to allow for complete fusion upon the application of external pressure

N.

Shall - In this document the word “shall” is used to indicate requirements that are mandatory

O. P.

Shop Fabricate – Piping fabrication completed at the Contractor’s shop, normally remote to the jobsite Sidewall Fusion Bonding – See Saddle Fusion Bonding






1.5

D.

The Contractor shall be responsible for fabrication accuracy. Each piece shall be subject to check by the Buyer.

E.

Inspectors representing the Buyer shall have access at all reasonable times to all areas concerned with the fabrication, installation and testing of piping. Inspectors may reject materials, methods, procedures or work which fails to meet the requirements of applicable codes, specifications, procedures, drawings, purchase orders or manufacturer's installation instructions.

F.

Inspection Contractor representing the Buyer will perform UT-TOFD on HDPE butt fusion joints in accordance with Specification C-CS-50-013. Inspection Contractor will be brought to site to perform UT-TOFD at least twice: once at the beginning of the project, and once when the installation is completed; plus any other time in between at the Buyer’s discretion.

Site Conditions Refer to Section 1.1 - Related Specifications

2.

MATERIAL S RECEIVING, INSPECTION, AND STORAGE 2.1

Materials Receiving and Inspection A.

Within the storage area, pipe and fittings shall be segregated by material grade/manufacturer, size, and SDR rating.

B.

Upon receipt of materials, the Contractor shall visually inspect all pipe and fittings. Pipe and fitting dimensions shall be determined in accordance with the methods described in ASTM D2122. Workmanship and dimensions shall be within the tolerances stipulated in ASTM F714, D2683, D3261 and all other appropriate specifications.

C.

Items that contain defects shall be rejected or repaired; such injurious defects include: 1.

Defects that reduce the mechanical properties, such as internal or external surface






4. 2.2

Absorption of deleterious substances; avoid absorption of liquid hydrocarbons as it could solvate polyethylene material and leach out during fusion and contaminate the weld.

Pre- Installation Storage & Exposure to Weather A.

The site and its layout should provide protection against physical damage to the components. General requirements include sufficient area to accommodate piping components; room for handling and maneuvering around the equipment, and a relatively smooth, level surface free of stones, debris, or other material that could damage pipe or components, or interfere with handling

B.

To prevent injury and damage to pipes, dropping and/or rolling of pipes during uploading or handling shall be avoided. Avoid dragging pipe over gravel or rock

C.

Individual pipes should be laid straight, not crossing over or entangled with each other.

D.

Pipe may be placed on 100mm (4-inch) wide wooden dunnage, evenly spaced at 1.2m (4ft) intervals along the entire pipe length. Dunnage should not be inserted between the layers of pipe at the storage site

E.

Loose storage stacking height shall be in accordance with manufacturer requirements to minimize pipe ovalization, but should not exceed the following stacking height recommendations: NPS

8 10 12

Suggested Stacking Height (Rows) 6 5 4

NPS

22 24 26

Suggested Stacking Height (Rows) 2 2 2





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING J.

3.

Cold & Hot Weather Handling: 1.

Temperatures near or below freezing will reduce HDPE flexibility and increasing vulnerability to impact damage. Extreme caution is required to not drop components and to avoid any impacts with equipment.

2.

Extreme summer heat can affect the ovality and shape of pipe; it is recommended that products be periodically rotated to eliminate such deflection.

FUSION BONDING QUALIFICATION REQUIREMENTS 3.1

General A.

Bonding performed according to this specification shall conform to the ASME B31.3 code requirements, as applicable. Compliance with this specification and Buyer's approval of the BPSs and BPQRs shall in no way relieve the Contractor of responsibility for providing joints that are sound and suited to the services for which they are intended.

B.

No production bonding shall be carried out, except by specific agreement between Buyer and the Contractor, before each BPS and Bonder is qual ified according to code requirements.

C.

A qualified Bonding Procedure Specification (BPS) in accordance with ASME B31.3 paragraph A328 shall be supplied for each Manufacturer grade and each fusion joint type: 1.

Socket Fusion Joint

2.

Butt Fusion Joint

3.

Saddle Fusion Joint

4.

Longitudinal welds are not within the scope of this specification





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING H. 3.2

The BPS and BPQR shall be performed on the same HDPE resin and Manufacturer grade that will be used for production welds.

Bonding Procedure Specification (BPS) Requirements A.

B.

General 1.

Manufacturer recommended fusion practices, guidelines, and procedures, for their particular grade, shall be incorporated into each butt, socket, and saddle fusion BPS. Conflict between the Manufacturer’s recommendation and this specification shall be resolved by the Buyer.

2.

If the manufacturer is listed within PPI TR-33 or TR-41, the generic recommendations for butt-weld and saddle fusion welds, respectively, shall be used.

3.

The BPS shall meet all the requirements and recommendations of ASTM D2657.

Scope of the BPS 1.

The BPS shall clearly explain a detailed procedure for successfully creating HPDE fusion bonds, and must identify all pertinent information in the fusion process, including, but not limited to: heater plate temperature, heat (soak) time, bead melt size, interfacial pressure, and cooling period for each pipe size and SDR rating.

2.

The BPS shall specify, for both bonding operation and BPQR testing requirements, all required materials, the required tools and equipment, and methods for temperature measurement. Storage requirements for all materials, tools, and equipment shall be given.

3.

The BPS shall identify pre-bonding equipment inspection requirements. Inspection and data logging requirements shall also be identified.

4.

Attachment 1 is an example of an acceptable BPS and the requirements are mandatory. a.

In

the

case

of

conflict

between

these

requirements

and

Manufacturer






3. B.

After approval, the Bonder shall be assigned a unique identification symbol. The area adjacent to each production weld shall be permanently identified with this symbol. Appropriate records shall also be filed to ensure traceability. a.

Qualification of one BPS does not qualify a Bonder for any other bonding procedure.

b.

Re-qualification of Bonders is required if: (1)

Bonder or Bonding Operator has not used the BPS for a period of 6 months or greater.

(2)

There is valid reason to question the individual’s ability to fusion bond per the BPS.

The Contractor shall maintain a listing of all approved Bonders that can be audited by the Buyer at any time.

BPQR Destructive Testing Requirements 1.

Qualification fusion weld coupons and assemblies shall be destructively tested in accordance with the requirements in Attachment 3 of this specification.

2.

All qualification tests shall be completed by a third-party laboratory qualified to perform the required tests, and may be subject to audit by the Buyer.

3.

Required Destructive Testing: a.

As stipulated in B31.3 paragraph A328, a hydrostatic Burst Test in accordance with ASTM D1599 is required for each BPQR.

b.

All qualification coupons must satisfy the requirements for Heat Fusion of ASME B31.3 Table A341.3.2 “Acceptance Criteria for Bonds”.

c.

Each BPQR shall have a total of six (6) destructive mechanical tests as per Attachment 3 of this specification.





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING D.

E.

Pup-Pieces 1.

Pup-pieces, installed in-between long pipe lengths, shall be avoided since the difficulties inherent to such fusions are more likely to result in defective welds.

2.

Pup-pieces installed to make up a length shall be a minimum of 2 pipe diameters long or 300 mm (12 inches), unless authorized by the Buyer.

Pipe-Fitting Damage Dragging pipe strings or fittings along the ground at speeds above a walking pace (appr. 3.2 to 4.8 km/hr) can cause impact damage to the pipe, especially in cold weather. Avoid dragging, dropping, or impacting material during construction. See Section 2 for more information regarding safe handling, inspection, and storage.

F.

4.2

Pipe Internal Misalignment 1.

Internal misalignment shall be less than 10% of the pipe wall thickness.

2.

If the 10% misalignment is exceeded, use one of the following procedures listed in order of preference: a.

First, rotate the pipe or fittings to reduce misalignment to the acceptable tolerances.

b.

Use the internal lineup clamps (e.g. fusion equipment clamping jaws) to correct moderate out-of-round conditions.

c.

With approval of the Buyer, taper the wall of the component internally, if it is found that the wall thickness is not reduced below the minimum requirements of ASTM F714.

Field Testing, NDE, and Inspection A.

Inspection





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING B.

The recommendations of the Manufacturer shall be incorporated when developing a field installation procedure.

C.

Consult ASTM F1804 to determine the allowable tensile load that can be applied to HDPE pipe material during pull-in installation.

D.

Consult ASTM F714 to determine the allowable degree of deflection limits.

E.

Buried pipe installation shall be in accordance with Watermains Specification C-CS-10-007, Sanitary Sewer Specification C-CS-10-004, and Storm Sewer & Culvert Specification C-CS-10-005, whichever is applicable.

F.

The construction procedures & requirements for underground installation of thermoplastic pressure piping as stipulated by ASTM F1668 and ASTM D2774 shall be met.

G.

The following considerations, at-least, must be taken into account when submitting installation procedures: 1.

Manufacturer recommendations for piping installation

2.

Equipment rigging

3.

Preparation of the surface & pile bed (for above ground piping)

4.

Preparation of the trench bottom and procedure for placing the pipe in the trench (for buried piping)

5.

Considerations for permanent bending radius

6.

Consideration of pipe lateral movement, longitudinal movement, and deflection

7.

Spacing and size of anchors

8.

Connections to fittings and structures





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING 5.2

5.3

NDE General Requirements A.

NDE techniques, records, acceptance criteria, and additional general requirements for fittings and piping shall be in accordance with the applicable Specifications, Codes and Standards listed in paragraph 1.1 and 1.2 of this specification.

B.

NDE, except visual examination, shall be performed by personnel certified in accordance with ASNT recommended practice SNT-TC-1A. Other types of certification require written authorization by the Buyer.

C.

NDE procedures shall be submitted to Buyer for acceptance before examination. Other records, if requested, pertaining to inspection shall be made available to the Buyer.

Visual Examination Visual examination and evaluation of indications shall be in accordance with AWS G1.10M, ASME B31.3 paragraph A341, and Manufacturer recommendations. Butt, socket, and saddle joints: the weld zone shall be examined during all stages of fusion, including heating, joining, and cooling. If any defects are observed, then the weld shall be replaced.

5.4

5.5

Ultrasonic Examination A.

Ultrasonic Time of Flight Diffraction (UT-TOFD) examination and evaluation of indications shall be performed by Buyer’s Inspection Contractor in accordance with the specific details & requirements specified in Ultrasonic – TOFD Testing of HDPE Pipe Specification C-CS-50-13.

B.

The use of ultrasonic testing in a pulse-echo configuration is not sensitive to lack of fusion defects and shall not be used unless specifically required per Buyer request.

Mechanical Testing Requirements






The hydrostatic test pressure is a function of the testing fluid temperature, and shall be calculated in accordance with B31.3 paragraph A345.4.2(b). The test pressure need not exceed 1.5 times the design pressure.

3.

Pressure-tightness shall be determined based on visual inspection of the base material and fusion joints. Any leaking joints shall be replaced and re-tested.

4.

The following Manufacturer recommendations should be included in the procedure: a.

Pressure testing safety precautions

b.

Recommended testing medium

c.

Recommended testing temperature and temperature correction factors

d.

Test parameters such as:

NOTE!!!

6.

(1)

Test length

(2)

Air venting

(3)

Allowable pipe expansion

(4)

Make-up water allowances

(5)

Total allowable test time

These represent the minimum considerations for developing a hydrostatic testing procedure; other pertinent information shall also be included.

SAFETY REQUIREMENTS 6.1

General Safety Program A.

The Contractor shall provide the Buyer a copy of their internal safety program.



Specif icati on C-CS-50-005 Page 1 of 14 Att achmen t 1_Rev. C

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BONDING PROCEDURE SPECIFICATION REQUIREMENTS 1.

2.

GENERAL NOTES 1.1

The following example represents the minimum requirements that must be met when submitting a working BPS, and therefore the requirements are mandatory.

1.2

The methods presented here are based on experience and good industry practice. In the case of conflict between these requirements and any outside source (including Manufacturer recommendations), the Buyer shall resolve the dispute.

1.3

This BPS is for butt fusion joints only, although many of the requirements are relevant for socket and saddle fusion bonding procedures.

GENERAL HDPE BONDING INFORMATION 2.1

Important definitions and terminology: A.

Alignment jig: The alignment jig is composed of three basic parts: (1) a stationary clamping fixture and a movable clamping fixture for holding each o f the two parts to be fused in alignment; (2) a facer for simultaneously preparing the ends of the components to be joined; and (3) appropriate adapters for different pipe sizes. Alignment jigs may be either manually or hydraulically powered.

B.

Butt fusion: A fusing of polyethylene materials per a qualified procedure that entails squaring and aligning the component materials; heating the component ends to a condition as described by the qualified procedure; pressuring the two aligned ends together as required by the qualified procedure; and a cooling time that is predetermined by the qualified procedure thereby resulting in the joining of two components which will exhibit a hydrostatic strength equal to or greater than




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2.2

F.

NPS: “Nominal Pipe Size” based on the steel pipe sizing standard ASME B36.10M

G.

Point of Fusion: The end of pipe or fitting which is available for trimming, heating, and pressing together during the heat fusion process.

H.

Shall: In this document the word “shall” is used to indicate requirements, which are mandatory.

Important Notes on Fusion A.

Reliable fusion joints can be accomplished under a reasonable latitude of conditions. The following is a listing of general notes to help ensure proper use of equipment and fusion techniques: 1.

Correct heater plate temperatures – Heater plate thermometers shall be tested for accuracy with a surface pyrometer.

2.

Adequate fusion pressures – The interfacial pressure (IFP) shall be specified by the pipe Manufacturer. As shown in paragraph 2.1D, the IFP and total gauge pressure are not identical.

3.

Severe ambient temperature conditions – Extreme heat, cold, and wind will alter heating and cooling times. Care must be taken to ensure that fusion times and procedures compensate for these temperatures to produce correct fusion joints. Should any question exist, the joint or joints should be subjected to nondestructive ultrasonic examination. Care shall also be used to ensure that the fusion process is protected from rain, snow or other conditions of excessive moisture.

4.

Double check fusion technique – Contact pressures and heating/cooling cycles may vary dramatically according to component size and wall thickness. Operators should not rely exclusively on the fusion equipment for joint qualification. Each bond shall be visually inspected in accordance with this specification and Manufacturer guidelines.




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING during this cycle the melt will roll out and give a “cold joint” fusion. During this cycle the Bonder shall look for an evenly distributed melt pattern while heating the component ends. WARNING: The heat fusion equipment is not explosion-proof and should not be used in a potentially volatile atmosphere. 3.

BONDING PROCEDURE 3.1

This procedure is for the operation of fusion equipment when performing heat fusion butt joints on High Density Polyethylene (HDPE) pipe and fittings.

3.2

The principle of heat fusion is to heat two surfaces to a designated temperature, and then fuse them together by application of a sufficient force. This force causes the amorphous materials to flow and mix, thereby resulting in fusion. When fused according to this procedure, the joint area becomes as strong as or stronger than the pipe itself in both tensile and pressures properties.

3.3

The seven basic steps involved in making a butt fusion joint are: 1.

Pre-bonding inspection and preparation

2.

Securely fasten the components to be joined

3.

Face the component ends

4.

3.4

Align the components profile

5.

Melt the component interfaces

6.

Join the two profiles together

7.

Hold under pressure

Pre-bonding Considerations:




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING prior to any work. Irregardless of the ambient temperature, if there are excessive wind gusts, rain, or snow the fusion area must also be hoarded prior to any fusion bonding.

F.

3.5

2.

The component surfaces to be joined should be protected from ice, frost, snow, dirt, and other contaminates prior to, during, and after fusion operations. Contamination of any kind can cause fusion defects or “cold welds”. Ice or frost may cause slippage of the alignment jigs during fusion and must be eliminated.

3.

The cold weather considerations of ASTM D2657 Annex A1 and Manufacturer recommendations shall be incorporated.

4.

Ice, snow, and rain make conditions troublesome for handling equipment and personnel. Unsure footing and traction require greater care and caution to prevent damage or injury. Avoid dropping or impacting HDPE components with equipment.

Hot Weather Considerations: 1.

Extreme summer heat can affect the ovality and shape of pipe; it is recommended that products be periodically rotated to eliminate such deflection.

2.

Extreme heat may also increase the required cooling time for the bond to reach full strength.

Properly arrange the fusion machine on level ground with an adequate number of pipe roller supports and clamps to allow easy component loading and positioning into the fusion machine.

3.6 All surfaces, heater plate, and components ends must be cleaned and dried. A.

General dust and light soil may be removed by wiping the surfaces clean with a dry, clean, lintfree cloth. Heavier soils may be washed or scrubbed off with soap and water solutions, followed by thorough rinsing with clean water and drying with clean, lint-free cloths.




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3.9

Securely fasten the components to be joined: A.

Secure each component in the machine by clamping; however there must be sufficient extension into the mid zone of the machine for facing, adjustment, and final facing after alignment adjustments.

B.

Move the component ends together to check for gross misalignment between the two component ends and make any adjustments using the machine allowances, if necessary. Alignment may be improved by rotating one of the pieces 90 degree to 180 degree

Complete initial facing of the component ends: A.

With the facing plate rotating, apply light pressure until a continuous ribbon of polyethylene appears from each facer blade location. 1.

Observing the facing plate as it progresses with the facing operation will dictate adjustments to the appropriate level of pressure.

2.

Never start or stop the facing procedure with the component ends in contact with the facer plate. Always move the component towards or away from the facer plate while it is rotating.

3.

Initially face the component ends so that the alignment of the component can be checked prior to facing to the “stops” (the “stops” will prevent further facing unless the component is reset in the machine). In doing so, extra material is available in the event adjustments are needed and additional facing is required to re-square the component ends.

4.

Align the components’ profile as stipulated in paragraph 3.10 of this BPS, prior to final facing.

3.10 Align the components’ profile:




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING 3.11 Final facing of components’: A.

After alignment has been verified or corrected to the acceptable tolerances, proceed to face until the stops are engaged preventing further facing. 1.

A minimum of one (1) complete revolution on each component end must be completed in order to expose clean material suitable for butt fusion.

2.

Always face to the stops to ensure a square face-off perpendicular to the component.

B.

All adjustments for component alignment, or delays of more than 15 minutes following facing, should be followed by additional facing to maintain proper alignment of the component ends or to remove potential contamination.

C.

Do not touch the pipe surfaces at any time after this step. Oil from hands or gloves will contaminate the pipe ends and could cause a poor bond. Only use a clean, dry, untreated, lintfree cloth to remove pipe chips or foreign matter.

D.

No sudden movements, impacts, or jerking motions of the components or equipment is permitted.

3.12 Measure hydraulic drag factor (pressure) of system: A.

Measure the drag factor to ensure the p roper compensation has been applied to the fusion force. In most cases, the drag factor will be the inherent drag in the hydraulic components of the machine. However, to assure this has not changed due to the system set-up (i.e. ground slope or length of pipe being moved); it should be checked, for each weld, using the fusion equipment manufacturer’s approved procedures. 1.

Slowly adjust upward the machine hydraulic control to initiate carriage movement. The system’s drag factor is the gauge pressure at which the carriage starts to move slowly (i.e.




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING the heater plates. Therefore, use this reading only as a general indicator (i.e. “go” or “nogo” gauge). C.

Place the heater plate between the component ends and move the ends against the heater plate with sufficient (moderate) force to ensure complete circumferential contact against the plate. Ensure that the plate does not come into contact with the pipe until the heater plate is securely in-place.

D.

After a uniform melt swell bead forms on the plate surface around the circumference of both components, REMOVE THE PRESSURE, and set the equipment to the minimum pressure setting to maintain contact. 1.

Begin recording the “soak time” from this point forward. Any excess applied pressure will cause the melt on the pipe to roll out and could give a “cold joint”.

2.

If the melt bead does not expand out flush to the heater plate, but curls away significantly from the heat plate (i.e. concave appearance), this is due to unacceptable pressure during heating.

E.

Continue to hold the components in place at minimum pressure for the BPS recommended “soak time”. Periodically inspect to ensure a uniform melt swell bead is maintained around the entire component circumference.

F.

Following the “soak time” the approximate melt swell bead width should be as follows: Pipe Size (NPS) 1-1/4 to 3

Ap pr ox im ate Melt Swel l Bead Width 1/8” (3 mm) 1/8”-3/16” (3 mm)




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING H.

QUICKLY inspect the component ends for hydrocarbon permeation/contamination, which is indicated by a rough, sandpaper-like, bubbly, or pockmarked surface after contact with the heater plate. Discoloration or hydrocarbon fuel odor may also occur. 1.

I.

If a non-uniform bead pattern is obtained or hydrocarbon permeation is observed, allow the pipe to cool, cut off the pipe ends, and repeat the facing, alignment, and heating procedures.

Ensure that all heating information is recorded on the fusion bonding report (Attachment 05).

3.14 Join the two profiles together: A.

B.

The required gauge pressure during joining will vary depending on the fusion equipment manufacturer, machine type, pipe size, SDR, and the required IFP. The calculation requirements are given in ANNEX 2 of this BPS. 1.

An interfacial pressure (IFP) of 414-621 kPa (60-90 psi) shall be used as required per PPI TR-33.

2.

The drag force (or pressure) must be taken into account when determining the TOTAL GAUGE PRESSURE.

After the heater plate has cleared the fusion zone, immediately initiate movement to bring the melted ends together. The transfer time after starting heater plate removal and re-contacting the component ends together should not exceed the following: Pipe Size (NPS) 3 and smaller 4 to 12

Maximum Transfer Time (Seconds) 4 6




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING component size, heater plate temperature setting, and environmental conditions: cooling time may be longer in extreme heat. B.

Allow the joint to cool an additional thirty (30) minutes, minimum, outside of the fusion machine before subjecting the fusion joint to any high stress, pulling, bending, installation, or rough handling. Recommended Cooling Period Wall Thickness Cooling Time

4.

Up to 0.2” (5 mm)

(minutes) 5

0.2” to 0.4” ( 5 – 10 mm) 0.4” to 0.6” (10 – 15 mm) 0.6” to 0.8” (15 – 20 mm) 0.8” to 1.2” (20 – 30 mm) 1.2” to 1.4” (30 – 35 mm) 1.4” to 1.8” (35 – 46 mm) 1.8” to 2.2” (46 – 56 mm) 2.2” to 2.6” (56 – 66 mm) 2.6” to 3.0” (66 – 76 mm)

5 – 10 10 – 15 15 – 20 20 – 30 30 – 40 40 – 55 55 – 70 70 – 85 85 - 100

DESTRUCTIVE AND NON-DESTRUCTIVE TESTING 4.1

During evaluation for bonding performance qualification, the requirements of B31.3 paragraph A328, ASTM D2657, and this project specification shall be met. A.

All BPQRs shall include a Quick Burst Test in accordance with ASTM D1599.




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6.

The replacement joints shall be re-established in accordance with the seven basic steps noted in this BPS.

ANNEX 1 - HEAT FUSION BUTT JOINT VISUAL INSPECTION GUIDELINES 6.1

The visual inspection guidelines given below are not intended to replace Code or specification requirements, i.e. Table A341.3.2 of ASME B31.3 or Annex IX of AWS G1.10M. They are intended to provide guidance for conducting visual inspection on heat fusion butt joints.

6.2

Manufacturer Recommendations for visual inspection shall also be used to verify butt fusion joints.

6.3

The gap (A) between the two single beads, or weld undercut, must not be below the fusion surface throughout the entire circumference of the butt joint.

6.4

The displacement (V) between the fused ends must not exceed 10% of the pipe/fitting minimum wall thickness or 1/16” (1.5 mm); whichever is less.




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Refer to the table below for general guidelines for bead width (B) for each respective wall thickness.

Min Wall Thickness

.118” (3 mm) .157” (4 mm) .197” (5 mm) .246” (6 mm) .315” (8 mm) .354” (9 mm) .433” (11 mm) .512” (13 mm) .63” (16 mm) .71” (18 mm) .75” (19 mm) .87” (22 mm) .94” (24 mm)

Ap pr ox im ate Bead Width B Min. 5/32” (4 mm) 5/32” (4 mm) 3/16” (4.8 mm) ¼” (6 mm) 9/32” (7 mm) 5/16” (8 mm) 11/32” (8.7 mm) ⅜” (9.5 mm) 7/16” (11 mm) ½” (12.7 mm) ½” (12.7 mm) ½” (12.7 mm) 9/16” (14.3 mm)

Max. ¼” (6 mm) 9/32” (7 mm) 5/16” (8 mm) 11/32” (8.7 mm) ⅜” (9.5 mm) 7/16” (11 mm) ½” (12.7 mm) 9/16” (14.3 mm) 19/32” (15 mm) ⅝” (16 mm) 11/16” (17.4 mm) 11/16” (17.4 mm) ¾” (19 mm)

Min. wall Thickness

1.06” (27 mm) 1.18” (30 mm) 1.34” (34 mm) 1.57” (40 mm) 1.77” (45 mm) 1.97” (50 mm) 2.16” (55 mm) 2.36” (50 mm) 2.56” (65 mm) 2.76” (70 mm) 2.95” (75 mm) 3.15” (80 mm) 3.35” (85 mm)

Ap pr ox im ate Bead Width B Min. 19/32” (15 mm) ⅝” (16 mm) 21/32” (16.7 mm) 11/16” (17.4 mm) 25/32” (19.8 mm) ⅞” (22.2 mm) 15/16” (23.8 mm) 1” (25.4 mm) 1 ⅛” (28.6 mm) 1-3/16” (30.1 mm) 1 ¼” (31.7 mm) 1-5/16” (33.3 mm) 1 ⅜” (34.9 mm)

Max 25/32” (19.8 mm) 13/16” (20.6 mm) ⅞” (22.2 mm) 29/32” (23 mm) 1” (25.4 mm) 1-1/16” (27 mm) 1-3/16” (30.2 mm) 1 ¼” (31.7 mm) 1-7/16” (36.5 mm) 1 ½” (38.1 mm) 1-9/16” (40 mm) 1-11/16” (42.8 mm) 1 ¾” (44.4 mm)




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6.9

B.

Improper heating times – During the heat soak cycle check to ensure the component gets proper heating time required by the BPS. Look at the bead size during heating and after fusion to make sure that ample time has been given for heat soak.

C.

Pressure applied during heating – When heating the component, it is important to note that there should only be uniform contact made with the heating surface and component end. There should not be any pressure applied to the heating surface while heating the component ends.

D.

Heating tool surface contaminated – Use approved cleaning methods prior to bonding and use necessary precautions to avoid environmental contamination of the heater plate surface.

E.

Improper cooling times – The component can never have too much time to cool. No matter the circumstances, if the fusion joint is too hot to touch then additional cooling is necessary.

Butt Fusion Joint Troubleshooting Guide: Defect Present

One bead large than the other

Bead not rolled over to pipe surface Square-type outer bead edge Excessive double bead width Flat top on bead Beads too small Beads too large Rough, sand-paper like, bubbly, or pockmarked melt bead surface

At tr ib ut in g Facto rs Misalignment, component slipped in clamp, worn equipment, incomplete facing, one side of the heater plate is hotter than the other, non-uniform pressure applied to pipe ends Shallow v-groove - insufficient heating & insufficient joining force Deep v-groove – insufficient heating & excessive joining force Pressure during heating Overheating, excessive joining force Excessive joining force, over-heating Insufficient heating or joining force Excessive heating time Hydrocarbon contamination




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The actual pressure setting on the fusion machine is the Hydraulic Gauge Pressure, or TOTAL GAUGE PRESSURE. It is a combination of both IFP requirements and a drag factor, as shown below:

TOTAL GAUGE PRESSURE = OD t IFP TEPA

= = = =

Drag Factor

=

(OD − t ) × t × π × IFP TEPA

+ Drag

Factor

Pipe outside Diameter, inch Wall Thickness, inch Recommended Interfacial Pressure, psi Total Effective Piston Area – depends on equipment manufacturer & piston 2 type, inch Hydraulic fusion pressure required to move the carriage holding the pipe, psi

7.3 An example of calculating the Gauge Pressure is shown below: Material = IFP = Pipe size = OD = SDR = Drag Factor = TEPA =

PE3408 75 psi NPS 8 8.625 inch 11 30 psi 2 4.710 inch

NOTE: The drag factor must be calculated for each fusion joint in conformance with this BPS. TEPA is dependent on Fusion Machine manufacturer and model. Calculations:

OD

8.625

0 784"

Client Name: Project Name: Project Number:


Specif icati on C-CS-50-005 Page 14 of 14 Attachment 1_Rev. C

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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING Machine Type NPS Piston Area

OD [inches (average)]

Pressure (psi) System Drag Factor must be added to obtain TOTAL GAUGE PRESSIRE

SDR 32.5 High

8 – 24” STD

XX.XX 2 in

12 – 36” STD

XX.XX 2 in

8 10 12 14 16 18 20 22 24 12 14 16 18 20 22 24 26 28 30 36

Low

SDR 28 High

SDR 21

Low

High

Low

SDR 17 High

Low

SDR 15.5 High

Low

SDR 13.5 High

Low

SDR 11 High

Low

SDR 9 High

Low

SDR 7.3 High

Low

SDR 6.3 High

Low

8.625 10.750 12.750 14.000 16.000 18.000 20.000 22.000 24.000 12.750 14.000 16.000 18.000 20.000 22.000 24.000 26.000 28.000 30.000 36.000

Notes: 1) Verify if piston is “Standard” or “High Velocity” for the applicable model of equipment being used. 2) Select the appropriate pressure based on the diameter of component being bonded. 3) The Drag factor must be added to this pressure to obtain the TOTAL GAUGE PRESSURE

Y:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 ATTA CHMENT 1.DOC

PIPING

Clien t Name: Project Name: Project Number:





HDPE BONDING PROCEDURE QUALIFICATION RECORD (BPQR) BONDING PROCEDURE QUALIFICATION RECORD NO.: BPS N0.

DATE:

Date:

REV NO.

WELDING PROCESS(ES):

TYPES:

PIPE CLASSIFICATION (ASTM D3350)

PIPE WALL THICKNESS (ASTM F714)

Type

Actual OD Size

Grade

Minimum Wall

Size

Nominal ID Size

Rating

Weight

Color BASE MATERIAL Material Properties

Test Method

Material Designation Cell Classification Density Flow Rate Flexural Modulus, 2% Secant Tensile Strength @ Ultimate Tensile Strength @ Yield Ultimate Elongation

PPI/ASTM ASTM D3350 ASTM D1505 ASTM D1238(190/21.6) ASTM D790 ASTM D638 ASTM D638 ASTM D638

Units

Nominal Value PE3408 Grade PE34

gm/cc gm/10 min. MPa MPa MPa %





FIELD FABRICATION AND INSTALLATION OF HDPE PIPING TECHNIQUE

ENVIRONMENTAL CONDITIONS

Alignment

Weather Condition

Cleaning

Air Temperature

Melt Temperature

Surface Temperature

Melt Time

Dewpoint

Interfacial Pressure

Relative Humidity

Drag Factor

Wind Speed (km/hr)

Fusion Gauge Pressure Hold Time Post Cooling Time Bead Removal (Optional) EQUIPMENT

Manufacturer Model No. Piston Area TEST METHOD 1 – QUICK BURST

Test Performed: Test Parameters: Test Results:

ASTM D 1599 – Method B as required per ASME B31.3 – 2002




FIELD FABRICATION AND INSTALLATION OF HDPE PIPING TEST METHOD 3 – TENSILE TEST Test Performed:

Tensile Test

Additional Tests: Test Parameters: Test Results: (include any re-tests)

INSERT PICTURE ILLUSTRATING TENSILE TEST STRAP

TEST METHOD 4 – DROP WEIGHT IMPACT TEST Test Performed:

Drop Weight Impact Test

Additional Tests: Test Parameters: Test Results: (include any re-tests)

INSERT PICTURE ILLUSTRATING IMPACT TEST STRAP





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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING BONDING PROCEDURE QUAL IFICATION TESTING REQUIREMENTS 1.

GENERAL REQUIREMENTS 1.1

1.2

General A.

The following specification identifies the procedures used for testing of High Density Polyethylene (HDPE) pipe joints for the purpose of qualifying the fusion Bonding Procedure Specification (BPS) and/or a Bonder.

B.

The fusion bonding procedure shall be in accordance with ASME B31.3 paragraph A328 and project Specification C-CS-50-005.

C.

All coupons must satisfy the requirements for Heat Fusion of ASME B31.3 Table A341.3.2 “Acceptance Criteria for Bonds” and all other referenced specifications.

D.

All destructive qualification tests outlined in this specification, including the examination of destructive bent strap test results, shall be completed by a qualified third-party laboratory.

Documentation A.

After completion of the tests outlined below, the Contractor shall submit a Bonding Procedure Qualification Record (BPQR) in accordance with Attachment 2 of this specification.

B.

The BPQR must include all required information to identify the BPS, Bonder or Bonding Operator, and the test results.

C.

The BPQR must identify the third-party lab that completed the qualification testing.




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HYDROSTATIC AND BURST TESTS 2.1

Test Assembly A.

2.2

2.3

1.

When the largest size to be bonded is NPS 4 or smaller, then the test assembly shall be the largest size to be joined. When the largest size to be bonded is NPS 4 or larger, the size of the test assembly shall be between 25% and 100% of the largest piping size to be joined, but a minimum of NPS 4.

2.

If readily available, the largest and thickest wall pipe shall be selected for qualification testing.

Burst Test Method A.

Follow the requirements of ASME B31.3 paragraph A328.2.5. The test assembly shall be subjected to a burst test according to the applicable sections of ASTM D1599. The time to burst in this standard may be exceeded.

B.

The test is successful if failure initiates outside of the bonded joint. If failure is at the bonded joint, then the test is a failure and the qualification test must be re-completed.

Hydrostatic Test Method A.

3.

The test assembly shall be fabricated in strict accordance with the candidate BPS. The size of pipe and fittings in the assembly are outlined in ASME B31.3 p ar. A328.2.5, as follows:

Unless specified by the Buyer, this test method shall not be used.

DESTRUCTIVE TESTING




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING c. D. E.

Complete the side-bend test utilizing a full rotation of approximately 180 degrees, and/or until the ends of the specimen touch. Acceptance Criterion: 1. 2.

3.3

The use of inside-root or outside-face bends is not recommended as the external bead/flashing may interfere with the bending process.

A specimen shall “pass” if it does not fail during the full rotation, and Passes the examination methods described in paragraph 3.6.A.

Tensile Testing Procedure: A.

One (1) coupon shall be cut from a random 120 degree section of the bond. Refer to Figure 1.

B.

The specimen shall be machined to the size requirements of ASTM D638 and the weld joint shall be aligned perpendicular to the axial loading direction. 1.

The maximum thickness limit for D638 specimens is 14 mm (0.55 in). Pipe thinner shall be used in the as-received thickness. Pipe thicker shall be milled to suit the dimensional requirements.

2.

At the Buyer’s discretion, multiple specimens can be produced and tested. Pipe material equal to or greater than 28mm (1.1in) may have two specimens prepared; pipe greater than 42mm (1.65in) may have three specimens, pipe greater than 56mm (2.2in) may have 4 specimens, and so on.

3.

All machining marks and notches must be removed prior to testing. Such defects can cause premature failure and will invalidate the test results.




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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING C.

3.5

Acceptance Criterion: 1.

A failure within 360 degrees of rotation indicates poor fusion quality. The qualification has failed.

2.

Failures that occur beyond 360 degrees may be considered acceptable and shall be assessed according to the examination procedures specified in paragraph 3.6.

Impact Test Procedure A.

For butt and socket joints only, one (1) coupon shall be extracted from a random 120 degree section of the bond. Refer to Figure 1. The coupon dimension are based on ASTM D2657, refer to Figure 2. 1. 2.

The coupons shall be cut square so that there are two sets of parallel surfaces. All machining marks and notches must be removed prior to testing. Such defects can cause premature failure and will invalidate the test results.

B.

Saddle fusion joints shall be tested in accordance with ASTM F905.

C.

Butt and socket fusion joints shall be drop weight impact tested using an apparatus as described in ASTM D2888. 1.

Use a “Tup Type A” impactor with a mass of at-least 13.6kg. Ensure that the equipment can obtain at-least a 3m free-fall height.

2.

Ensure that there is sufficient clamping support so the specimen does not move during testing. Align the specimen such that the tup impacts a machined side of the specimen (see Figure 4). Avoid impacting the bead flashing as this can invalidate the impact results.




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3.

c.

Bending the specimen at least 45 degrees from the horizontal axis, or

d.

If the specimen obtains an impact value of 680N m (500lbf ft) or higher, and does not fail by any of the mechanism described above, then stop impact testing that specimen. ▪

▪

Measure the combined height (m) and force (N) that initiates failure; record this as the Candidate Weld Impact Value (J or N m). ▪

4. F.

3.6

Record the fracture appearance of the failure(s).

Acceptance Criterion: 1.

If the Candiate Weld Impact Value is not equal to or greater than the Reference Impact Value, the qualification has failed.

2.

For Candiate Weld Impact Value that meets the Reference Impact Value, the specimen shall be evaluated per the procedures of paragraph 3.6.

3.

Tests of 680N m (500lbf ft) or higher impact with no failures shall “pass”, pending examination per the procedures of paragraph 3.6.A. ▪

▪

Examination of Mechanical Tests: A.

Visual Inspection 1.

Visually inspect the coupon for cracks, porosity, or other defects as per Manufacturer recommendations, ASTM D2657, AWS G1.10M, and ASME B31.3 Table A341.3.2.

2.

If no visual defects are present, the weld is acceptable. If defects are observed in any single specimen, the entire qualification has failed.




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C.

1.

With approval, re-test specimens from the same weld spool may be destructively tested per the methods of this specification.

2.

Alternatively, ultrasonic time of flight diffraction (UT-TOFD) may be used to verify integrity.

If one of these re-test coupons were to fail, then the entire qualification must be re-started.

NOTE: 3 COUPONS PER SECTION

120°

120°



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Figure 2 – Side-Bend Testing of HDPE





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FIELD FABRICATION AND INSTALLATION OF HDPE PIPING 15 t 15 t (150mm min) (150mm min) t 1-1/2 t (25mm min)

TEST STRAP BUTT FUSION 15 t (150mm min)

15 t (150mm min)

t 1-1/2 t (25mm min)

TEST STRAP SOCKET FUSION




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Clamping Vice Grips (typical)

IMPACT

Prepared Surface

CL 6t (75mm min)

Weld Bead Flashing 6t (75mm min)

Figure 4 – Drop Weight Impact Testing




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DATE: ________________________________________

AMB IENT TEMPERATURE: _________________

CONTRACTOR: ________________________________

WIND SPEED: ____________________________

FUSION BONDER: ______________________________

RAIN or SNOW: ___________________________

FUSION MACHINE TYPE: ________________________

FUSION MACHINE NUMBER:_______________

PRE-PRODUCTION BONDING CHECKLIST: NOTE: This form shall be completed at the beginning of each fusion b ondin g produ ction s hift.

Item

Inspection Procedure

1

HEATER PLATE

Acceptance Criteria

- thermostat operating, calibrated

- calibration records

- plate surface - plate heating

- clean, free from scratches - uniform temp ±5.6°C

Contractor Inspector

Buyer Inspecto r

Client Name: Sociedad Minera Cerro Verde S.A.A Project Name: Primary Sulfide Project Project Number: PSP108

Specification C-CS-50-005 Page 1 of 2 Attachment 5_Rev. C

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DATE: ___________________________________

AMBIENT TEMPERATURE: _____________________

WIND SPEED: CONTRACTOR: ___________________________ _________________________________ FUSION BONDER: _________________________

RAIN or SNOW: _______________________________

FUSION MACHINE TYPE: ___________________

FUSION MACHINE NUMBER: ____________________

BONDING CHECKLIST AND FUSION DATASHEET LOG: ITEM

Inspection Procedure

1

TRIAL FUSION

- Visual Examination - UT-TOFD examination 2

FUSION BONDING

- record fusion number

Acceptance Criteria

- visual acceptance criteria - UT-TOFD acceptance criteria

Contractor Inspector

Buyer Inspector

Hdpe Field

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