Anda di halaman 1dari 9

YANACOCHA PROJECT

MINERA YANACOCHA S.R.L. PROJECT N 04463500 YANACOCHA PROJECT

TECHNICAL SPECIFICATION FD N 000 250 50130 MYSRL N 4635-5-SPC-102


FOR

HDPE PIPE INSTALLATION AND FUSION BONDING


Prepared by:

FLUOR DANIEL
APPROVED BY

Lead Engineer Project Engineer Engineering Manager Client


REV. A B 0
COMMENTS:

Jos L. Crdova David Lee Roger Chapman Simon Briggs

BY J.R. J.R. J.R.

ISSUE Issued for review and client approval Issued for quotation Issued for construction

DATE 25/Feb/02 08/Mar/02 22/Mar/02

CHK'D J.L.C. J.L.C.

TECH. APPROVAL J.L.C. J.L.C.

Client Name: Minera Yanacocha S.R.L. Project Name: Yanacocha Project Contract Number: 04463500 FLUOR DANIEL 1.0 GENERAL 1.1 Summary A. Scope of Specification

Project Specification 000 250 50130 Date 22/Mar/02 Page 2 of 7 Rev 0

This specification covers the installation, handling, fusion bonding, inspection and testing for highdensity polyethylene (HDPE) piping. B. Related Specifications 000.250.50003: 1.2 References The publications listed below form part of this specification. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for construction. All work included in this specification shall conform to the applicable provisions of these publications: A. ASME (American Society of Mechanical Engineers), B31.3 Process Piping. B. ASTM (American Society for Testing and Materials), D2657 Standard Practice for Heat-Joining Polyolefin Pipe and Fittings. 2.0 GENERAL REQUIREMENTS 2.1 Care shall be taken not to strike the pipes when unloading so as not to damage the surface. It is important to protect the ends to avoid deterioration that alters the welding process. Textile, not metal rope, shall be used when unloading rolls or piping so as not to scratch the piping. Length of piping shall be stored on a flat surface without point loads, arranged in layers. Pipe bigger than 500 mm (20) diameter shall only be piled in two layers and secured in order that they do not move. If wood spacers are used, they shall not be further than 2 meters apart. The maximum pile height is 2 meters. Coordinates, dimensions and elevations are indicated in the drawings. The Contractor shall verify the routing to confirm any change that may exist. All lines are identified in the P&IDs and in the piping drawings, in concordance with Specification 000.250.50003 Piping Material. The different routes of the piping and curve radius are indicated in the drawings. However, the curve radius shall not be lower than that indicated below for an installation environmental temperature of 20C: Nominal Pressure kg/cm 2.5 3.2 4.0 6.0 10.0 Admissible Curve Radius R 50 D 40 D 30 D 20 D 20 D Piping Material (MYSRL N 4635-6-SPC-036).

2.2

2.3 2.4 2.5

D: Outside diameter of the HDPE piping. 2.6 If the laying is done at 0C, the curve radius indicated shall be increased by a factor of 2.5. The curve radius can be determined by linear interpolation from 0 to 20C.

165877876.doc

Piping Engineering

Client Name: Minera Yanacocha S.R.L. Project Name: Yanacocha Project Contract Number: 04463500

Project Specification 000 250 50130 Date 22/Mar/02 Page 3 of 7 Rev 0

FLUOR DANIEL 2.7 The piping should be handled, stored, cut, welded, installed and tested in strict accordance with the Manufacturers instructions, which will take priority over this Specification in the event of conflict. 3.0 MATERIALS The HDPE piping materials will be furnished by others and will be in accordance with Specification 000.250.50003 Piping Material, or an approved substitute. 4.0 INSTALLATION 4.1 Excavation and Preparation of the Bedding for Buried HDPE Pipe When piping can be welded in long stretches outside of the ditch, narrow ditches may be used to install the piping after welding, provided that there is no twisting or bending and the maximum curve radio is maintained. Minimum ditch width shall be equal to nominal diameter plus 30 cm. The minimum depth of the piping laying shall be according to the design drawings, which will depend on the outside diameter and of the loads produced by the circulation of wheel-driven vehicles. The support bed in the ditch shall be made using fine sand 10 cm thick, consolidated by slight compaction before laying the piping. Once the piping is placed in the bed, it shall be covered up to 30 cm above its upper part using compactable material with no rocks. 4.2 Precaution when laying piping When lowering the piping into the ditch bed, avoid causing forced stress or deformations. The end must be protected when stretching the piping using a rubber guard. Stretching on rocky ground or rocks is not permited. The maximum draw stress for HDPE piping, F, shall be calculated using the following formula: F = (d-S) S x T where: d = S = T = Outside pipe diameter (cm) Pipe thickness (cm) Maximum allowable material stress (70-120 kg/cm)

The Contractor shall be responsible for any mistreatment of the piping during transfer or drawing and shall replace all damaged pipe with no additional cost. Welded fittings must be moved as little as possible. Piping must not be loading on top of fittings. The tees, elbows and reductions must not be raised without supporting the weight of the long sections of piping. 4.3 When laying HDPE piping on the surface, it is important to consider the changes in temperature, both external as well as internal, since they can cause significant linear displacement. HDPE piping has a percentage of black coal that protects it from ultraviolet rays, but the heat it absorbs increases the expansion and contraction rate, so it must be protected either by covering it or painting it white.

165877876.doc

Piping Engineering

Client Name: Minera Yanacocha S.R.L. Project Name: Yanacocha Project Contract Number: 04463500

Project Specification 000 250 50130 Date 22/Mar/02 Page 4 of 7 Rev 0

FLUOR DANIEL When expansion occurs, the piping will be deflected laterally, for which available space must be left. However, when it contracts, it will become taught between two anchors. 5.0 FUSION BONDING PIPE 5.1 General A. Qualified personnel using qualified bonding procedure specifications (BPS) that are acceptable to Yanacocha shall perform all fusion bonding. The Contractor is responsibLe for qualifying all bonding personnel, inspectors and procedures at his expense prior to performing production fusion bonding. B. The Contractors fusion bonding personnel and the bonding procedure specification (BPS) to be used shall be qualified by actual fusion bond testing on site in accordance with ASME B31.3, Chapter VII, Part 9 and the requirements of this specification. C. These bonding procedures shall not be used to bond polymers of different chemistries such as HDPE to PVC, HDPE to PP, HDPE to PB, etc. 5.2 Submittals A. All manufacturers data, procedures, and records shall be submitted to Yanacocha for review well in advance of performing any production joints. All progress and quality inspection reports shall be submitted to Yanacocha on a daily basis, unless otherwise directed. One (1) copy of all manufacturers data, procedures, records and inspection reports shall be retained on site. B. Procedures The Contractor shall submit written procedures for environmental and safety control, qualified fusion bonding (BPS), inspection, quality control and repair prior to performing any production joints. Each bonding procedure specification shall include the HDPE material, thickness, diameter, joint type (e.g., butt, socket, branch, etc.), and the cool down time required before the fused joint can be moved, buried, or pressure tested. Each bonding procedure specification (BPS) shall inciude an easy to read table of fusion bond machine settings for pressures, time and temperatures for the fusion bonding process. The table shall inciude information for each combination of size and wall thickness of HDPE pipe used on the project. C. Records The Contractor shall submit performance qualification records (PQR) for all personnel that will be performing heat fusion joints. The Contractor shall also submit qualification records for all personnel that will be performing inspection of heat fused joints. 5.3 Personnel A. The candidates for qualification as pipe fusion bonders shall be experienced in the operation of HDPE fusion bonding machines and shall attend at least 4 hours of classroom instruction and 4 hours of field or shop training regarding HDPE fusion welding as it relates specifically to the Project. This training shall include the same HDPE pipe material, sizes and wall thicknesses to be fusion bonded for the Project and the same equipment to be used in the fusion bonding process. To be qualified, the bonders shall make fusion bonds that have successfully passed a hydrostatic pressure test. The fusion bonders shall also be made thoroughly familiar with this Project Specification. B. Qualified fusion bonding personnel shall be assigned a unique symbol or number for use in identifying the person making the fusion bond. This symbol may be a die punch used to form the impression into the hot fusion bond bead. Personnel doing the fusion bonding shall mark each weld using this symbol.

165877876.doc

Piping Engineering

Client Name: Minera Yanacocha S.R.L. Project Name: Yanacocha Project Contract Number: 04463500 FLUOR DANIEL 5.4 Procedures

Project Specification 000 250 50130 Date 22/Mar/02 Page 5 of 7 Rev 0

A. Pipe fusion bonding shall be performed in accordance with the HDPE pipe manufacturers printed instructions in conjunction with the pipe fusion bonding machine manufacturers printed instructions, ASTM D2657, the contract requirements, and the requirements of this specification for the sizes shown on the drawings. B. The fusion-welding machine shall be adjusted to the proper pressure and heat for each different size pipe. The settings shall be verified with trial samples. No fusion bonding shall be performed if it is raining or if the air temperature is less than 4C (40F). The joints should be protected from wind during the fusion process. C. All surfaces to be bonded shall be dry and free of dirt, moisture, oil, grease, paint and other contaminants. This requirement also applies to the heater plates. Metal tools should not be used to clean heater plates. 6.0 PIPING SUPPORTS The aerial piping supports are defined in the design drawings, but if ground bracing must be added, the following guidelines will be followed: The supports must be capable of preventing lateral and longitudinal movements. If, on the other hand, the pipe has been designed to move during expansion, sliding supports must be provided with an unrestricted leader in the directon of the movement. The use of U-bolts is not permitted; clamps will be used with a soft spacer (rubber) between the clamp and the pipe. If the weight of the pipe and temperature of the fluid are high (temperature above 60C), continuous supports must be used. Heavy parts or fittings and flanged joints must be supported on both sides. Piping and fittings must be anchored in order to prevent their lateral displacement due to changes in temperature. Pipe supporting in suspended lines shall be according to manufacturers recommendations.

7.0 INSPECTION AND TESTING 7.1 General A. Each system will be hydrostatically tested according to Piping Pressure Testing Specification 000.250.50050. B. All fusion bonding shall be inspected to the extent specified below by personnel who have been qualified by the Contractor to carry out all inspections in accordance with the requirements of this specification. C. The piping shall be mounted to ensure the inside cleaning of the same, and once tested hydraulically, plugs should be placed on the ends to avoid the entry of foreign materials. 7.2 Personnel

165877876.doc

Piping Engineering

Client Name: Minera Yanacocha S.R.L. Project Name: Yanacocha Project Contract Number: 04463500

Project Specification 000 250 50130 Date 22/Mar/02 Page 6 of 7 Rev 0

FLUOR DANIEL A. The candidates for qualification as HDPE fusion bonded joint inspectors shall have a background in one of the following: (1) quality control of HDPE pipe fusion welding, (2) equivalent experience and training in the fusion bonding of HDPE pipe, or (3) acceptable experience in the installation of HDPE pipe. B. The candidates for qualification as HDPE fusion bond inspectors shall also attend at least 4 hours of classroom instruction and 4 hours of field or shop training regarding the inspection of HDPE fusion welds as it relates specifically to the Project. Training shall be conducted using the HDPE pipe material, sizes and wall thicknesses to be fusion bonded on the Project and the equipment to be used in the fusion bonding process. The inspectors shall also be made thoroughly familiar with this Project Specification. 7.3 Extent of Inspection The Contractor shall inspect and document on the HDPE Fusion Bond Joint Inspection Documentation Form (see attachment 1) the minimum inspection points specified below. The following inspection points shall be witnessed by Yanacocha unless a written waiver has been issued by Yanacocha. A. Prior to the making of the first fusion bond at the start of work on each shift. B. After the completion of the first fusion bond. C. Any time pipe material, diameter or wall thickness changes. D. Whenever the ambient temperature changes more than 11C (20F). E. Prior to the making of every fourth fusion bond. F. After the completion of every fourth fusion bond. 7.4 Acceptance Criteria The completed HDPE fusion bonds shall be visually inspected for acceptability based on the following acceptance criteria. A. The fusion bond bead must be continuous and consistent in size around the entire girth of the pipe. B. The double HDPE fusion bond beads shall be uniform. C. There shall be no undercut of the outside edges of the HDPE fusion bond bead. D. The total width of the double fusion weld bead should be 2 to 2 times the height of the bead from the pipe surface. E. There shall be no gaps or voids visible between the fusion bond beads. F. There shall be no misalignment of the pipe ends. G. There shall be no porosity in the fusion bond bead. H. The fusion bond is considered unacceptable if any of the above acceptance criteria are not met. 7.5 Testing by Contractor A. Ultrasonic testing may be performed in addition to the visual inspection.

165877876.doc

Piping Engineering

Client Name: Minera Yanacocha S.R.L. Project Name: Yanacocha Project Contract Number: 04463500

Project Specification 000 250 50130 Date 22/Mar/02 Page 7 of 7 Rev 0

FLUOR DANIEL B. When the machine butt fusion technique is used, the Contractor shall perform destructive testing of trial samples at the start of each shift and anytime the material, diameter or wall thickness of the pipe changes. A destructive test shall also be made if the heating time changes due to a change in the ambient temperature. The trial sample shall be used to determine joint integrity, and to verify the operator procedure and the fusion bonding machine set-up. C. The primary destructive fusion bond test to be used shall be the bend strap test on trial fusion bond samples. The bend strap test is prepared by making a trial fusion bond and allowing it to cool to ambient temperature. A test strap that is at least 15 pipe wall thicknesses long on each side of the fused joint, and about 1- wall thicknesses wide shall be cut from the pipe. D. The strap shall be bent so that both ends of the strap touch. Any disbondment or cracking at the fusion bond is unacceptable. If failure occurs, fusion procedures and/or machine set-up shall be changed and a new trial fusion bond and test strap specimen prepared and tested. Production fusion bonding shall not proceed until a test joint has passed the strap test. A test strap from thick wall may require considerable pressure to bend. 7.6 Testing by Yanacocha Yanacocha reserves the right to randomly select production joints to be destructively tested to confirm joint integrity. These joints will be submitted to an outside laboratory for tensile testing and impact testing in accordance with procedures and standards approved by Yanacocha. The expense of testing shall be borne by the Contractor if such testing indicates the joint was defective. 7.7 Repairs of Welded Joints The Contractor shall remove and replace, at his expense, all production joints that are either defective or fail to meet the inspection and testing criteria of this specification. Any defects disclosed after inspection or pressure testing shall also be removed and replaced by the Contractor at his expense. All rewelds shall be inspected and tested in the same manner as the original work. 8.0 ATTACHMENTS Attachment 01: HDPE Fusion Bond Joint Inspection Documentation Form

End of Specification

165877876.doc

Piping Engineering

Client Name: Minera Yanacocha S.R.L. Project Name: Yanacocha Project Contract Number: 04463500

Project Specification 000 250 50130 Date 22/Mar/02 Attachment 01- Sheet 1 of 1 Rev 0

FLUOR DANIEL HDPE FUSION BOND JOINT INSPECTION DOCUMENTATION FORM Joint No._____________ Pipe WalI Thickness _______________ Pipe Diameter__________________ Date: ________________ Time: ___________ 1.0 WeId Made By: ________________

Result of destructive testing required by paragraph 5.5 (If applicable).

2.0 2.1 3.0 3.1 3.2 3.3 3.4

Welding machine settings:

Time: ________

Temperature: ___________ Pressure: __________

Air temperature __________________ Wind __________________ Humidity_________________ Visual: The weld bead must be continuous and consistent in size around the entire girth of the pipe. Acceptable: ________ Not Acceptable: ________ The HDPE weld bead shall be uniform. Acceptable: ________ Not Acceptable: ________ There shall be no undercut on the outside edges of the HDPE weld bead. Acceptable: ________ Not Acceptable: ________ The width of the double fusion weld bead should be 2 to 2 times the height of the weld bead from the pipe surface. Acceptable: ________ Not Acceptable: ________ There are no gaps or voids visible between the weld beads. Acceptable: ________ Not Acceptable: ________ There is no misalignment of the pipe ends. There is no porosity in the weld bead. Ultrasonic testing if required. Acceptable: ________ Acceptable: ________ Not Acceptable: ________ Not Acceptable: ________

3.5 3.6 3.7 4.0

Acceptable: ________ Accepted / Rejected By:

Not Acceptable: _________

____________________________________ Comments:

165877876.doc

Piping Engineering