Hdpe Field

Sociedad Minera Cerro Verde S.A.A.
Primary Sulfide Project

Project No. PSP108
Field Fabrication and Installation

of HDPE Piping
Construction Specification
No. C-CS-50-005
Rev. C
14 March 2005
Y:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 HDPE - REV. C.DOC

Client Name: Sociedad Minera Cerro Verde S.A.A. Specification C-CS-50-005
Project Name: Primary Sulfide Project Page 1 of 14
Project Number: PSP108 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the superceded copies.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 Originator Rev Revision Description

No. (name/initials) Date
C Yiu-Tak Tse 14Mar05 Issued for Approval
; New Issue Entire Specification Re-issued
APPROVALS ORIGINAL SIGNED BY

FLUOR DATE CLIENT DATE
Project Manager:
Engineering Manager: Brad Matthews 14Mar05
Area Project Engineer: Janis Zeidaks 14Mar05
Lead Discipline Engineer: Bill Li 14Mar05
Process Approval:
Y:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 HDPE - REV. C.DOC PIPING

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Mining & Minerals
Table of Contents
1. GENERAL .....................................................................................................................................................3
1.1 Summary .......................................................................................................................................................3
1.2 References ....................................................................................................................................................3
1.3 Terminology ...................................................................................................................................................4
1.4 Quality Assurance .........................................................................................................................................5
1.5 Site Conditions ..............................................................................................................................................6
2. MATERIALS RECEIVING, INSPECTION, AND STORAGE........................................................................6
2.1 Materials Receiving and Inspection...............................................................................................................6
2.2 Pre- Installation Storage & Exposure to Weather .........................................................................................7
3. FUSION BONDING QUALIFICATION REQUIREMENTS ...........................................................................8
3.1 General ..........................................................................................................................................................8
3.2 Bonding Procedure Specification (BPS) Requirements ................................................................................9
3.3 Bonding Procedure Qualification Record (BPQR) Requirements.................................................................9
4. EXECUTION OF FIELD FUSION BONDING AND INSTALLATION.........................................................10
4.1 Pipe and Fitting Field Fabrication................................................................................................................10
4.2 Field Testing, NDE, and Inspection.............................................................................................................11
4.3 Bonding Repair............................................................................................................................................11
4.4 Field Installation...........................................................................................................................................11
5. INSPECTION, NDE AND TESTING REQUIREMENTS FOR HDPE FUSION JOINTS.............................12
5.1 General Inspection Requirements...............................................................................................................12
5.2 NDE General Requirements........................................................................................................................13
5.3 Visual Examination ......................................................................................................................................13
5.4 Ultrasonic Examination................................................................................................................................13
5.5 Mechanical Testing Requirements ..............................................................................................................13
5.6 Hydrostatic Leak Testing .............................................................................................................................13
6. SAFETY REQUIREMENTS ........................................................................................................................14
6.1 General Safety Program..............................................................................................................................14
6.2 Reporting Accidents ....................................................................................................................................14
7. ATTACHMENTS .........................................................................................................................................14

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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 Density Polyethylene (HDPE) in pressure applications. Pipe and
fittings bonded per this specification shall satisfy the requirements for ASME B31.3 for pressure
piping applications.
1. Any deviation from this specification requires written authorization from the 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.
B. 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
6. C-SP-50-001 Piping Line Class
C. Work Not Included

1. Unloading of material at the jobsite or the Contractors shop
2. Buyer supplied materials and services
1.2 References
All fusion bonding, examination, and testing shall conform to the applicable requirements of the latest
editions and revisions of standards and codes issued by the following authorities as of
November 1, 2004:
A. ASME (American Society of Mechanical Engineers)
B31.3 Process Piping
B. ASNT (American Society of Nondestructive Testing)
SNT-TC-1A Recommended Practice for Qualification of Nondestructive

Examination (NDE) Personnel
C. ASTM (American Society for Testing and Materials)

1. D1599 Standard Test Method for Resistance to Short-Time Hydraulic Failure
Pressure of Plastic Pipe, Tubing, and Fittings

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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
D. AWS (American Welding Society)
G1.10M Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds
E. NFPA (National Fire Protection Agency)
NFPA 24 Standard for the Installation of Private Fire Service Mains and Their
Appurtenances
F. PPI (Plastics Pipe Institute)

1. TN-13 General guidelines for Butt, Saddle, and Socket Fusion of unlike
Polyethylene Pipes and Fittings
2. TR-33 Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe
3. TR-41 Generic Saddle Fusion Joining Procedure for Polyethylene Gas Piping
1.3 Terminology
All terminology shall be in accordance with ASTM F412. Those terms commonly used in this
specification are listed below.
A. Bonder Person performing and responsible for the fusion bonding process.
B. Bonding Operator See Bonder
C. BPS - Bonding Procedure Specification
D. BPQR Bonding Procedure Qualification Record

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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 Owners 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. Shop Fabricate Piping fabrication completed at the Contractors shop, normally remote to the
jobsite
P. Sidewall Fusion Bonding See Saddle Fusion Bonding
Q. Socket Fusion Bonding A joint in which the joining surfaces of the components are heated, and
the joint is made by inserting one component into the other
R. Standard Dimension Ratio (SDR) A specific ratio of the average specified outside diameter to
the minimum specified wall thickness (Do / t) for outside diameter-controlled plastic pipe
S. Technician - The technician is a person hired by the Inspection Contractor and is responsible for
the UT-TOFD inspection and the interpretation of the results
1.4 Quality Assurance
A. Approved fabrication and bonding methods shall be used in compliance with project
requirements. Contractors Inspector shall monitor and review the activities of the
fabrication/installation crew to ensure that applicable codes, standards, and procedures are
being followed to meet project quality goals.
B. The Contractor shall examine and inspect piping components for damage and improper
manufacturing prior to beginning fabrication, in accordance with ASME B31.3, Paragraph 341.
After fabrication has been completed, components shall be re-examined and re-inspected for
possible damage. Repairs shall be made before installation.
C. Contractors inspectors shall examine and inspect the final product to ensure that Buyers quality
criteria had been met.

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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 Buyers discretion.
1.5 Site Conditions
Refer to Section 1.1 - Related Specifications
2. MATERIALS 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
gouges, scars, scratches, blisters, or discontinuities that produce a notch effect or reduce
the specified wall thickness by 5% or more.
2. Any kinking of the pipe during transport may be indicated by excessive plastic deformation
and/or wrinkle patterns on the pipe surface, and must be repaired. Any pipe misalignment
greater than 10% along the length of the pipe shall be repaired.
3. Pipe ovality, as defined below, shall not exceed the limits listed:
D AVE DMIN
% Ovality = * 100%
D AVG
Where: DMIN = minimum diameter at point of deflection
DAVG = average of maximum and minimum diameters at point of deflection
DR OVALITY LIMIT
(%)
> 21 5.0
17 4.0
15.5 3.5
13.5 2.5
11 2
<9 1.5

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4. Absorption of deleterious substances; avoid absorption of liquid hydrocarbons as it could

solvate polyethylene material and leach out during fusion and contaminate the weld.
2.2 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 Suggested NPS Suggested

Stacking Height Stacking Height
(Rows) (Rows)
8 6 22 2
10 5 24 2
12 4 26 2
14 4 28 2
16 3 30 2
18 3 32 2
20 3 >36 1
F. The base row must be blocked to prevent sideways movement or shifting. The removal of any
one pipe should not cause shifting or rolling of the remaining pipes
G. When several different wall thicknesses of pipe are received, it is recommended that the pipe be
segregated into different groups of similar size and wall thickness (SDR rating). If pipe of
different wall thickness must be stored together, place the thickest wall on the bottom with pipe
of progressively smaller wall thickness stacked on top. Consideration for the fusion joining
sequence should be taken when stacking dissimilar pipes
H. Pipe received in bulk packs or strip load packs should be stored in the same package; do not
remove tie-down straps or bands. If the storage site is flat and level, bulk packs or strip load
packs may be stacked evenly upon each other to an overall height of about 1.8m (6ft). For less
flat or less level terrain, limit stacking height to about 1.2m (4ft).
Before removing individual pipe lengths from bulk packs or strip load packs, the pack must be
removed from the storage stack, and placed on the ground
I. The interior of stored components should be kept free of debris and other foreign matter

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J. 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.
3. 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 qualified 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
D. The Contractor shall provide a BPQR for each BPS, in accordance with B31.3 paragraph A328
and this specification that demonstrates the candidate BPS produces sound fusion joints.
E. The Contractor shall be responsible for the quality of bonding performed by members of their
organization (and all sub-contractors), and shall conduct all required bonding performance
qualifications for each Bonder. Each Bonder shall have an individual BPQR, in accordance with
B31.3 paragraph A328 and this specification, which must be approved by the Buyer prior to
fabrication.
F. Fusion bonding shall not proceed until all BPQR documents are returned to the Contractor with
permission to proceed from the Buyer.
G. Bonding shall not be subcontracted to others without the written approval of the Buyer.

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H. The BPS and BPQR shall be performed on the same HDPE resin and Manufacturer grade that
will be used for production welds.
3.2 Bonding Procedure Specification (BPS) Requirements
A. 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 Manufacturers 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.
B. 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
recommendations, the Buyer shall resolve the dispute.
b. The gauge pressure requirements for all pipe sizes & SDR ratings, as a function of
machine & piston type, shall be submitted for approval as part of the BPS.
c. The BPS shall include visual inspection guidelines based on Manufacturer
recommendations and all applicable codes and standards.
C. Dissimilar Fusion Welds
If fusion of different HDPE resins or Manufacturer grade (e.g. different cell classification) is
required; a separate BPS must be submitted in accordance with this specification. The
guidelines of PPI TN-13 shall be used.
3.3 Bonding Procedure Qualification Record (BPQR) Requirements
A. General
1. The requirements for bonding procedure qualification are given in B31.3 paragraph A328.
The format for the BPQR is shown in Attachment 2 of this specification.
a. The Contractor shall submit a valid BPQR for each proposed BPS.
b. The Contractor shall also submit a valid BPQR for each fusion Bonder.

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2. 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 individuals ability to fusion bond per the
BPS.
3. The Contractor shall maintain a listing of all approved Bonders that can be audited by the
Buyer at any time.
B. 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.
4. If there is any ambiguity in the tests completed or the test results, the Buyer reserves the
right to institute further destructive or non-destructive tests, such as impact, torque, tensile
elongation, or ultrasonic examination to verify the quality of the BPS or Bonder.
4. EXECUTION OF FIELD FUSION BONDING AND INSTALLATION
4.1 Pipe and Fitting Field Fabrication
A. Fusion Procedures
1. All fusion joining shall be completed in strict accordance with the BPS for socket, butt, and
saddle fusion techniques approved for the project.
2. Any deviation from the approved BPS requires approval of the Buyer.
B. Pipe Substitutions
The standard dimensional ratio (SDR) shall be specified on all drawings. Substitutions of pipe,
including thicker or thinner wall materials, are not permitted without written authorization from
the Buyer.
C. Bead (Flash) Removal
The bead or flash may interfere with slipping lap joint flanges against the stub end. The
procedures for removal of any weld beads shall be submitted for approval.

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D. 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.
E. 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. 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.
4.2 Field Testing, NDE, and Inspection
A. Inspection
1. The Contractors inspection program shall ensure all fusion bonds are inspected per
project requirements.
2. Pre-bonding and in-situ inspection checklists and weld data logs shall be maintained by
the Contractor for all fusion joints, and shall equal or exceed the requirements indicated in
Attachment 4 and 5. These forms shall be submitted to the Buyer no later than the next
working day.
3. The use of data loggers on all fusion equipment is mandatory, but shall be used to verify
and not replace the requirements of Attachment 4 and 5.
B. Field testing, NDE, and other inspection requirements (including hydrostatic leak testing) are
outlined in Section 5.
4.3 Bonding Repair
Defective materials, joints, and other workmanship that fails to meet the requirements of ASME B31.3,
all referenced specifications, and this project specification shall be completely replaced at the
Contractors expense.
4.4 Field Installation
A. There are many factors, such as field environment, pipe size, and thickness that will affect the
installation procedures required. Prior to commencing such work, procedures for the field
installation of HDPE pipe material, above and below ground, shall be submitted for approval.

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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
9. Precautions for pressure testing
10. Safety Guidelines
5. INSPECTION, NDE AND TESTING REQUIREMENTS FOR HDPE FUSION JOINTS
5.1 General Inspection Requirements
A. Refer to Quality and Certification Requirements form in purchase order documents.
B. Refer to inspection and testing requirements contained in related specifications referenced by

this specification.
C. Inspections shall be performed as specified in Attachment 5 Piping Inspection and Heat

Treatment Summary of Piping Line Class Specification C-SP-50-001.
D. Inspection does not relieve the Contractor of the responsibility for:

1. Providing quality and workmanship that meet specification and code requirements
2. Performing examination and testing as required by this specification and applicable code
E. The Buyer shall be allowed free access to the Contractors facilities (both shop and field) to
audit, witness, and inspect all practices, methods, tests, and procedures to verify the
Contractors QA/QC program.

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5.2 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.
5.3 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 Ultrasonic Examination
A. Ultrasonic Time of Flight Diffraction (UT-TOFD) examination and evaluation of indications shall
be performed by Buyers 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.
5.5 Mechanical Testing Requirements
A. Unless otherwise noted in the Code and specifications, destructive mechanical tests shall not be
required for examining production welds; except at the request of the Buyer to verify fusion
and/or NDE quality.
B. As stipulated in paragraph 3.3 and Attachment 3 of this specification, destructive tests shall be
required during qualification testing of the BPS and Bonding Operator.
5.6 Hydrostatic Leak Testing
A. General
1. The intent of hydrostatic leak testing is to reveal gross faults in the piping system, not
confirm long-term performance of the pipeline.
2. Prior to initial operation, the piping system shall be hydrostatic leak tested in accordance
with paragraph A345 of ASME B31.3 and ASTM F2164 - Field Leak Testing of
Polyethylene (PE) Pressure Piping Systems Using Hydrostatic Pressure.
3. Pneumatic testing of thermoplastic piping is forbidden.
B. Hydrostatic Leak Testing Procedure Requirements

1. The Contractor shall submit a Hydrostatic Leak Testing Procedure for approval by the
Buyer prior to commencing any tests.

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2. 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:
(1) Test length
(2) Air venting
(3) Allowable pipe expansion
(4) Make-up water allowances
(5) Total allowable test time
NOTE!!! These represent the minimum considerations for developing a hydrostatic testing
procedure; other pertinent information shall also be included.
6. SAFETY REQUIREMENTS
6.1 General Safety Program
A. The Contractor shall provide the Buyer a copy of their internal safety program.
B. The Buyer will provide the Buyers safety procedures to the Contractor. The Contractor shall
attend all applicable on-site safety orientations and meetings.
6.2 Reporting Accidents
A. Any type of accident shall be reported to the Buyer immediately.
B. A lost time accident shall be followed by a written report. This report shall describe the accident
and any steps taken to avoid a reoccurrence.
7. ATTACHMENTS
Attachment 1 Bonding Procedure Specification Requirements
Attachment 2 HDPE Bonding Procedure Qualification Record (BPQR)
Attachment 3 Bonding Procedure Qualification Testing Requirements
Attachment 4 Pre-Production Bonding Checklist
Attachment 5 Bonding Checklist and Fusion Datasheet Log
End of Specification

Project Number: PSP108 Attachment 1_Rev. C
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BONDING PROCEDURE SPECIFICATION REQUIREMENTS

1. 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.
2. 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 of 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
the parent material.
C. Drag factor or Drag Pressure: The hydraulic pressure required to move the carriage that is
holding the component. This must be determined before each fusion as the drag factor (or drag
pressure) can vary depending on the weld setup, environment, and equipment. Generally
207kPa (30psi) is accepted as the minimum.
D. Hydraulic Gauge Pressure or TOTAL GAUGE PRESSURE: The conversion of interfacial

pressure to the gauge pressure as calculated by:
(OD t ) t IFP
Total Gauge Pr essure = + Drag Factor
TEPA
OD = Pipe Outside Diameter
t = Wall Thickness
IFP = Recommended Interfacial Pressure
TEPA = Total Effective Piston Area depends on equipment manufacturer &
piston type
Drag Factor = Hydraulic pressure required to move the carriage holding the pipe
E. Interfacial pressure (IFP): The pressure put on the end area of the component. This is not the
pressure setting that is to be set on the fusion machine, but the actual interfacial pressure on the
component. The PPI TR-33 recommended range is between 414-621kPa (60-90psi), but, this
number must be confirmed by the pipe Manufacturer.
Y:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 ATTACHMENT 1.DOC PIPING

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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.
2.2 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.
5. Use adequate cooling times An important parameter in the fusion process is adequate
cooling time. All joints should remain stationary at least until the joint can be touched with
the bare hand or as specified in the BPS, whichever is the longer cooling time. An
additional 30 minutes of cooling, outside of the fusion equipment, is required prior to
severe working/handling or pressure testing of the component.
6. Dirt, oil and debris Any of these substances on the heater plate, component ends, facer
or any surfaces that contact the fusion surface can cause improper fusion. Even airborne,
invisible pollutants can contaminate a heater plate. Ensure that all equipment and
component ends are clean.
7. Cleaning of component ends avoid wiping the areas after facing operation. If shavings or
other debris must be removed, use only a dry, clean, lint-free cloth.
8. Equipment maintenance Heater surfaces are generally coated with a non-stick material.
Cleaning techniques should be used accordingly. Clean heater surfaces after each fusion.
When the heater plate is not in use, be sure to use a heater insulator holder; this ensures
that the contact surfaces of the heater remain clean and at a uniform temperature, and also
prevents inadvertent contact that can result in burn injuries.
9. Heat soak cycle It is important not to put pressure on the heater plate during the heat
soak cycle, the cycle starts after the component has made 100% interfacial contact with
the heater surfaces and melt is observed around the circumference. If pressure is applied

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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. Align the components profile
5. Melt the component interfaces
6. Join the two profiles together
7. Hold under pressure
3.4 Pre-bonding Considerations:
A. Prior to performing any fusion bonding, the equipment shall be inspected by the Bonder for
operability and proper maintenance in accordance with the checklist in Attachment 4 of this
project specification.
1. All equipment, gauges, and other devices shall be calibrated prior to production welding,
and re-calibrated in 3-month intervals thereafter. Written verification shall be required.
2. The equipment manufacturers recommendations for maintenance shall be followed.
Defective, improper, or un-authorized tools and equipment are not acceptable.
B. Prior to commencing full production fusion welds, a trial fusion must pass both visual and UT-
TOFD examination as required in this specification.
C. During the fusion process, the Bonder shall visually inspect the fusion bonding process and
record all data in accordance with the checklist in Attachment 5. The Contractors and Buyers
inspector shall approve all records of fusion bonding.
D. The use of electronic data loggers shall be used to complement, but not replace, the information
recorded in Attachment 5.
E. Cold Weather Considerations:

1. Record the ambient temperature and prevailing wind speed. If the ambient temperature, or
wind chill equivalent, is below 4.4C (40F) the fusion area must be hoarded and heated

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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.
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.
F. 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.
3.5 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, lint-
free 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.
B. The heater faces that come into contact with the component ends shall be clean, oil-free, and
coated with a nonstick coating (per Manufacturer recommendations) to prevent molten material
from sticking to the heater surfaces.
1. Any remaining plastic material from prior fusion welds can interfere with fusion quality and
must be removed per Manufacturers instructions. Do not use metal tools that can scratch
the coating.
2. Before using any chemical cleaning solvents, the manufacturers instructions and material
safety data sheets (MSDS) shall be consulted for safe handling. Some solvents may leave
residue on the pipe ends or may be incompatible with the material. PPI Technical Report
TR-19 Thermoplastic Piping for the Transport of Chemicals, and/or the Manufacturer
specifications shall be referenced for information on chemical compatibility. Any candidate
cleaning solvent shall be submitted for approval prior to any fusion qualification testing or
production fusion welds with the candidate cleaning solvent.
3. If the non-stick coating becomes excessively worn or scratched, the heater plate shall be
recoated.
3.7 Set the heater plate temperature; normally the PPI TR-33 generic range of 204 C 232 C (400F
450F) is required. Plug in the heater plate and insert into the protective, insulated box.

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3.8 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
3.9 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:
A. The component ends must be rounded and aligned with each other to minimize mismatch (high-
low) of the pipe walls.
B. The use of pipe support stands (and other necessary equipment) will allow the component to be
brought into the fusion machine on a level plane, which will greatly help in alignment and reduce
drag on the moveable jaws.
C. Although perfect alignment is preferred and is typically possible under normal circumstances, the
maximum misalignment shall not exceed 10% of the nominal wall thickness or 1.5mm (1/16),
whichever is less.
1. Do not use your finger to check high-low misalignment. Always keep your hands free of the
jaw region.
D. Move the component ends together to re-check that alignment is within the 1.5mm (1/16)
tolerance; no gaps, spaces, or voids are allowed. Adjust alignment accordingly within the
machine allowances. Minor misalignment may be corrected by tightening the inside clamps at
the high-side until the outside diameters of the pipe ends match. Never loosen the jaw clamps or
the pipe may slip during fusion.

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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, lint-
free 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 proper 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
manufacturers approved procedures.
1. Slowly adjust upward the machine hydraulic control to initiate carriage movement. The
systems drag factor is the gauge pressure at which the carriage starts to move slowly (i.e.
crawl).
2. During drag pressure measurements, ensure that no pipe slippage in the jaws occurs.
3. Typically a minimum of 207 kPa (30 psi) is required to initiate carriage movement.
B. Ensure that this information is recorded on the fusion bonding report (Attachment 5).
3.13 Heat the component interfaces:
A. Identify the component size and thickness (SDR); select the correct heating protocol (i.e. heating
temperature and anticipated soak time).
B. A calibrated pyrometer shall be used to verify that the heater plate surface is between
204-232C (400-450F) prior to the first joint of each shift, and then periodically re-verified at
least 4 times throughout the shift.
1. Using the calibrated pyrometer, check the actual plate surface temperature at 45 degree
intervals on both surfaces of the heater plate. The allowable temperature variance is
10C. Templestiks shall not be used on the plate surfaces.
2. Once calibrated, record the reading on the heating tools dial thermometer that indicates
internal temperature. This dial does not accurately indicate surface temperature because
there is some heat loss from internal to external surfaces depending on factors such as
ambient temperature, wind conditions, loose heater plates, and foreign material between

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the heater plates. Therefore, use this reading only as a general indicator (i.e. go or no-
go 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 Approximate Melt Swell Bead

Width
(NPS)
1-1/4 to 3 1/8 (3 mm)
4 to 8 1/8-3/16 (3 5 mm)
10 to 12 3/16 to (5 6 mm)
13 to 24 to 7/16 (6 11 m)
26 to 36 Approximately 7/16 (11 mm)
40 to 63 Approximately 9/16 (14 mm)
1. The approximate bead size data and soak time shall be based on Manufacturers
recommendations.
2. Depending upon prevailing weather and jobsite conditions, the time required to reach the
melt bead size may vary.
a. One area of the plate may be hotter than others, this can occur on cool sunny days
whereby the sun locally heats the top of the cold pipe. It may be necessary to
insulate the top of the pipe. Wind, rain, or snow may also cause uneven pipe and/or
heater plate temperatures; use appropriate hoarding and heating to compensate.
b. During cold weather fusion, do not increase the heater plate temperature outside of
the recommended range to reduce the required soak time. Allow the melt swell bead
width to develop by using a longer soak time within the allowable temperature range.
G. Once the appropriate melt swell bead width is established, commence component pull-back from
the heater plate. When the component ends have been separated from the heater plate, quickly
remove the heater plate from the fusion zone and place in the heater insulator.

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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. 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.
I. Ensure that all heating information is recorded on the fusion bonding report (Attachment 05).
3.14 Join the two profiles together:
A. 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.
B. 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 Maximum Transfer Time

(NPS) (Seconds)
3 and smaller 4
4 to 12 6
13 to 24 9
26 to 36 12
40 to 63 15
C. Bring the melted ends together with enough force such that both beads roll-over towards each
component surface. The bead roll-over shall be uniform around the entire circumference of the
joint; then STOP moving the component ends together and hold at the required total gauge
pressure.
1. Do not use excessive force such that all molten material is extruded out of the joint and a
cold weld forms.
2. The Bonder shall ensure the pipe does not slip in the jaws during joining.
3. No water or any other contaminates shall be allowed to enter the fusion zone 150 mm to
200 mm (6 - 8) on either side of the fusion joint.
D. Ensure that all joining information is recorded on the fusion bonding report (Attachment 5).
3.15 Hold and cool under pressure:
A. Maintain total gauge pressure until the component is at-least cool to the touch or the
Manufacturers recommended Cooling Period, whichever is longer. The time will vary with

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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
(minutes)
Up to 0.2 (5 mm) 5
0.2 to 0.4 ( 5 10 mm) 5 10
0.4 to 0.6 (10 15 mm) 10 15
0.6 to 0.8 (15 20 mm) 15 20
0.8 to 1.2 (20 30 mm) 20 30
1.2 to 1.4 (30 35 mm) 30 40
1.4 to 1.8 (35 46 mm) 40 55
1.8 to 2.2 (46 56 mm) 55 70
2.2 to 2.6 (56 66 mm) 70 85
2.6 to 3.0 (66 76 mm) 85 - 100
4. 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.
B. Bent Strap Tests, in accordance with ASTM D2657 and Appendix 03, shall also be required.
4.2 During both qualification and production welds, each fusion joint shall be visually inspected per
ANNEX 1 of this specification.
4.3 Production welds shall also be subject to random UT-TOFD examination in accordance with project
specification C-CS-50-005, as stipulated by the Buyer
4.4 When specified, prior to initial operation the piping system shall be hydrostatic leak tested in
accordance with paragraph A345 of ASME B31.3 and ASTM F2164 - Field Leak Testing of
Polyethylene (PE) Pressure Piping Systems Using Hydrostatic Pressure.
4.5 Pneumatic testing of thermoplastic piping is forbidden.
5. UNACCEPTABLE BUTTWELD FUSION JOINTS
5.1 Butt fusion joints that do not meet the acceptance criteria as noted in ANNEX 1 of this procedure,
Manufacturer recommendations, or any Code or specifications listed in Specification C-CS-50-005
paragraph 1.1 & 1.2 shall be completely removed. All fusion joints are subject to visual inspection.
5.2 Any fusion joints that do not meet the acceptance criteria for UT-TOFD examination, as noted in
Specification C-CS-50-013, shall be completely removed.

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5.3 The replacement joints shall be re-established in accordance with the seven basic steps noted in this
BPS.
6. 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.
6.5 The outer bead must be rolled back fully against the wall of the pipe/fitting.
Proper Roll-Back
Improper Roll-Back

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

Thickness Bead Width B Thickness Bead Width B
Min. Max. Min. Max

.118 (3 mm) 5/32 (4 mm) (6 mm) 1.06 (27 mm) 19/32 (15 mm) 25/32 (19.8 mm)
.157 (4 mm) 5/32 (4 mm) 9/32 (7 mm) 1.18 (30 mm) (16 mm) 13/16 (20.6 mm)
.197 (5 mm) 3/16 (4.8 mm) 5/16 (8 mm) 1.34 (34 mm) 21/32 (16.7 mm) (22.2 mm)
.246 (6 mm) (6 mm) 11/32 (8.7 mm) 1.57 (40 mm) 11/16 (17.4 mm) 29/32 (23 mm)
.315 (8 mm) 9/32 (7 mm) (9.5 mm) 1.77 (45 mm) 25/32 (19.8 mm) 1 (25.4 mm)
.354 (9 mm) 5/16 (8 mm) 7/16 (11 mm) 1.97 (50 mm) (22.2 mm) 1-1/16 (27 mm)
.433 (11 mm) 11/32 (8.7 mm) (12.7 mm) 2.16 (55 mm) 15/16 (23.8 mm) 1-3/16 (30.2 mm)
.512 (13 mm) (9.5 mm) 9/16 (14.3 mm) 2.36 (50 mm) 1 (25.4 mm) 1 (31.7 mm)
.63 (16 mm) 7/16 (11 mm) 19/32 (15 mm) 2.56 (65 mm) 1 (28.6 mm) 1-7/16 (36.5 mm)
.71 (18 mm) (12.7 mm) (16 mm) 2.76 (70 mm) 1-3/16 (30.1 mm) 1 (38.1 mm)
.75 (19 mm) (12.7 mm) 11/16 (17.4 mm) 2.95 (75 mm) 1 (31.7 mm) 1-9/16 (40 mm)
.87 (22 mm) (12.7 mm) 11/16 (17.4 mm) 3.15 (80 mm) 1-5/16 (33.3 mm) 1-11/16 (42.8 mm)
.94 (24 mm) 9/16 (14.3 mm) (19 mm) 3.35 (85 mm) 1 (34.9 mm) 1 (44.4 mm)
3.54 (90 mm) 1 (38.1 mm) 1-13/16 (46 mm)
6.7 The size differential (Smax Smin) between two single beads shall not exceed X% of the double bead
width (B).
S x 100
Where X =
B
S = Smax Smin
For pipe to pipe max X = 10%

For pipe to fitting max X = 20%
For fitting to fitting max X = 20%
6.8 Common Reasons for Fusion Joint Rejections
A. Inadequate facing of the component After facing the component ends, they need to be brought
together to make sure that they line up without gaps and with proper axial alignment.

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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.
6.9 Butt Fusion Joint Troubleshooting Guide:

Defect Present Attributing Factors
One bead large than the other 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
Bead not rolled over to pipe surface Shallow v-groove - insufficient heating & insufficient joining force
Deep v-groove insufficient heating & excessive joining force
Square-type outer bead edge Pressure during heating
Excessive double bead width Overheating, excessive joining force
Flat top on bead Excessive joining force, over-heating
Beads too small Insufficient heating or joining force
Beads too large Excessive heating time
Rough, sand-paper like, bubbly, or Hydrocarbon contamination
pockmarked melt bead surface
Double v-groove too deep Excessive joining force, insufficient heating, pressure during
heating
Non-uniform bead size around pipe Misalignment, defective heating tool, worn equipment, incomplete
facing
Third bead Excessive joining force
Flat top on bead Excessive joining force, overheating
7. ANNEX 2 REQUIRED CALCULATIONS FOR DETERMINING GAUGE FUSION PRESSURE
7.1 Interfacial pressure (IFP) is the pressure put on the end area of the component to be fusion bonded.
The PPI TR-33 recommended range is between 414-621kPa (60-90psi), but this number must be
confirmed by the pipe Manufacturer This is not the gauge pressure setting that is to be set on the
fusion machine.

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7.2 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:
(OD t ) t IFP
TOTAL GAUGE PRESSURE = + Drag Factor
TEPA
OD = Pipe outside Diameter, inch

t = Wall Thickness, inch
IFP = Recommended Interfacial Pressure, psi
TEPA = Total Effective Piston Area depends on equipment manufacturer & piston
type, inch2
Drag Factor = 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 = PE3408
IFP = 75 psi
Pipe size = NPS 8
OD = 8.625 inch
SDR = 11
Drag Factor = 30 psi
TEPA = 4.710 inch2
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
t= = = 0.784"
SDR 11
(8.625 0.784) 0.784 3.14 75

TOTAL GAUGE PRESSURE = + 30 psi = 338 psi
4.710
Therefore, the required TOTAL GAUGE PRESSURE setting on the fusion machine shall be
2230 kPa (338 psi).
7.4 Standard force pistons shall be used for fusion welds, unless specifically required by the
Manufacturer and approved by the Buyer.
7.5 The gauge pressure requirements for all pipe sizes & SDR ratings, as a function of machine & piston
type, shall be submitted for approval as part of the BPS. A sample table is shown below:

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Machine
Type Pressure (psi)
OD System Drag Factor must be added to obtain TOTAL GAUGE PRESSIRE
NPS
[inches
Piston (average)]
SDR 32.5 SDR 28 SDR 21 SDR 17 SDR 15.5 SDR 13.5 SDR 11 SDR 9 SDR 7.3 SDR 6.3
Area
High Low High Low High Low High Low High Low High Low High Low High Low High Low High Low
8 8.625
8 24 10 10.750
STD 12 12.750
14 14.000
16 16.000
XX.XX 18 18.000
2
in 20 20.000
22 22.000
24 24.000
12 12.750
12 36 14 14.000
STD 16 16.000
18 18.000
20 20.000
XX.XX 22 22.000
2
in 24 24.000
26 26.000
28 28.000
30 30.000
36 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

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HDPE BONDING PROCEDURE QUALIFICATION RECORD (BPQR)
BONDING PROCEDURE QUALIFICATION RECORD NO.: DATE:
BPS N0. 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 Units Nominal Value
Material Designation PPI/ASTM PE3408

Cell Classification ASTM D3350 Grade PE34
Density ASTM D1505 gm/cc
Flow Rate ASTM D1238(190/21.6) gm/10 min.
Flexural Modulus, 2% Secant ASTM D790 MPa
Tensile Strength @ Ultimate ASTM D638 MPa
Tensile Strength @ Yield ASTM D638 MPa
Ultimate Elongation ASTM D638 %
Environmental Stress Crack Resistance (ESCR) ASTM D1693 Failures%/hrs
ESCR Compressed Ring ASTM F1248 Failures%/hrs
Carbon Black (UV Protection) ASTM D1603 %
Elastic Modulus ASTM D638 MPa
Brittleness Temperature ASTM D746 C
Melting Point ASTM D789 C
Vicat Softening Temperature ASTM D1525 C
Hardness ASTM D2240 Shore D
Thermal Expansion ASTM D696 mm/mm/C
Volume Resistivity ASTM D991 Ohm-cm
Hydrostatic Design Basis (HDB) @ 73.4F ASTM D2837 MPa
Molecular Weight Category
Molecular Weight Average GPC
NOTES:
Y:\103\109 EngDoc\109.2 CONSPEC_CS\Piping\C-CS-50-005\C-CS-50-005 Attachment 2.doc PIPING

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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: ASTM D 1599 Method B as required per ASME B31.3 2002
Test Parameters:
Test Results:
(include any re-tests)
INSERT PICTURE ILLUSTRATING DUCTILE BURST OUTSIDE OF FUSION ZONE
TEST METHOD 2 SIDE-BENT STRAP TEST

Test Performed: Bent Strap Test
Additional Tests:
Test Parameters:
Test Results:
INSERT PICTURES ILLUSTRATING BENT STRAPS

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TEST METHOD 3 TENSILE TEST
Test Performed: Tensile Test

Additional Tests:
Test Parameters:
Test Results:
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:
INSERT PICTURE ILLUSTRATING IMPACT TEST STRAP
TEST METHOD 5 TORQUE TEST

Test Performed: Torque Test
Additional Tests:
Test Parameters:
Test Results:
INSERT PICTURE ILLUSTRATING TORQUE TEST STRAP
Bonders Name: Employee No.:
Test Conducted By: Laboratory Test No.:
Test Inspected By:
We certify that the statements in this record are correct and that the test fusion butt welds were prepared, bonded, and tested in
accordance with the requirements of B31.3 of the ASME Code, ASTM Specification requirements, specification C-CS-50-005.
Date: By:

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BONDING PROCEDURE QUALIFICATION TESTING REQUIREMENTS
1. GENERAL REQUIREMENTS
1.1 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.
1.2 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.
1.3 Required Qualification Testing Methods
A. The Burst Test Method as stipulated in ASME B31.3 paragraph A328.2.5 shall be used for
qualification of each BPS and Bonder. Hydrostatic test, in lieu of burst test, may only be used
when specifically requested by Buyer.
B. A total of six (6) destructive mechanical tests must pass for each bonder and BPS qualification
1. Three (3) side-bent strap tests
2. One (1) tensile test
3. One (1) drop-weight impact test
4. One (1) torque test
C. All destructive tests are qualitative means by which one can determine the difference between a
good and a poor bond.
D. Qualified third-party interpretations shall be required for all test specimens. The Buyer shall be
notified of all coupon failures.
E. If there is any ambiguity in the tests completed or test results, the Buyer reserves the right to
institute further destructive tests or ultrasonic examination (UT-TOFD) completed in accordance
with Specification C-CS-50-013 to verify the quality of the BPS or Bonder.
Z:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 ATTACHMENT 3.DOC PIPING

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2. HYDROSTATIC AND BURST TESTS
2.1 Test Assembly
A. 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 par. A328.2.5, as follows:
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.
2.2 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.
2.3 Hydrostatic Test Method
A. Unless specified by the Buyer, this test method shall not be used.
3. DESTRUCTIVE TESTING
3.1 Destructive mechanical testing can be very sensitive to small changes in geometry. Ensure that all
dimensional tolerances are within 2mm (1/16) during specimen preparation.
3.2 Side-Bent Strap Test Procedure
A. Three coupons shall be extracted from each 120 degree section of the candidate bond. Refer to
Figure 1. The coupon dimension are based on ASTM D2657, refer to Figure 3.
a. The coupons shall be cut square so that there are two parallel surfaces.
b. All machining marks and notches must be removed via machining prior to testing.
Such defects can cause pre-mature failure and will invalidate the test results.
B. Three 180 degree side-bend tests shall be performed.
C. Place the coupon in a vice with the bond bead approximately 25.4 mm (1) above the top of the
vice jaws. A long pipe should be used to make the bend with the edge of the pipe being located
25.4 mm (1) from the edge of the bead. See Figure 2.
a. Thicker wall specimens may require spacing greater than 25.4mm (1). Ensure that
the bead remains centered between the vice and pipe during the entire rotation.
b. If thin wall specimens begin to buckle, a thicker specimen may be cut and bent using
a 180 degree mandrel, similar to that used for bending metallic weld coupons.

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c. The use of inside-root or outside-face bends is not recommended as the external

bead/flashing may interfere with the bending process.
D. Complete the side-bend test utilizing a full rotation of approximately 180 degrees, and/or until the
ends of the specimen touch.
E. Acceptance Criterion:
1. A specimen shall pass if it does not fail during the full rotation, and
2. Passes the examination methods described in paragraph 3.6.A.
3.3 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 Buyers 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.
C. Test the weld coupon until failure using a constant strain rate and record the strength at yield,
strength at ultimate, and ultimate elongation.
D. Acceptance Criterion:
1. Compare the weld coupon mechanical properties (yield, ultimate, elongation) to the base
pipe material properties that must be reported on the BPQR (see Attachment 2). Any weld
coupon that does not meet or exceed these base material properties has failed the
qualification.
3.4 Torque Testing Procedure:
A. 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 3.
1. The coupons shall be cut square so that there are two sets of parallel surfaces.
B. Place the coupon in a vice with the bond bead located approximately 25.4 mm (1) above the top
of the vice jaws. A pipe wrench shall be used to twist (i.e. torque) the coupon a minimum of 360
degrees until the coupon failed, with the edge of the pipe wrench being located 25.4 mm (1)
from the edge of the bead.

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C. 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.
3.5 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. The coupons shall be cut square so that there are two sets of parallel surfaces.
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.
3. Impact testing is hazardous, use appropriate safety precautions to avoid injury.
D. Reference impact value of the drop weight impact test:

1. Prior to testing the candidate weld, determine the reference impact value for the pipe
grade, diameter, and SDR. Extract a base material sample from the same pipe spool as
the candidate weld. The coupon dimensions shall be based on Figure 3; and the
requirements for sample cutting, machining, and surface preparation, described above,
shall be met.
2. Measure the combined height (m) and force (N) that initiates failure; record this as the
Reference Impact Value (J or Nm).
3. Record the fracture appearance of the failure. A brittle fracture indicates poor base material
properties and the Buyer must be notified immediately.
E. Drop Weight Testing of Weld Coupons

1. Initially drop the weight from a height of at least 250mm (10in). Ensure the weight impacts
the approximate weld center line.
2. Increase the drop height in 50mm (2 in) intervals until failure occurs in the specimen by
one of the following mechanisms:
a. Failure of the base material
b. Failure of the weld

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

d. If the specimen obtains an impact value of 680Nm (500lbfft) or higher, and does not
fail by any of the mechanism described above, then stop impact testing that
specimen.
3. Measure the combined height (m) and force (N) that initiates failure; record this as the
Candidate Weld Impact Value (J or Nm).
4. Record the fracture appearance of the failure(s).
F. 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 680Nm (500lbfft) or higher impact with no failures shall pass, pending
examination per the procedures of paragraph 3.6.A.
3.6 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.
B. Failure outside of the weld zone:

1. Failure outside of the weld zone is acceptable. It indicates that the weld is of greater
integrity than the fitting or pipe.
C. Failure at the weld zone:

1. Ductile fracture:
a. Contact the Buyer. It may be acceptable if failure occurs in a ductile manner,
indicative of plastic deformation and tensile overload, while showing a distinct amount
of elongation; although further destructive and/or non-destructive tests are required
to verify fusion quality.
2. Brittle fracture:
a. If a coupon fails in a shear-like manner with a non-bonded brittle fracture face, the
entire weld has failed qualification.
3.7 Re-Testing of BPS Qualification Coupons
A. The Buyer reserves the right to institute further destructive or non-destructive tests to verify
the quality of the BPS or Bonder.
B. If a coupon has failed or there is any ambiguity in the tests results contact the Buyer:

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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.
C. 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
120
Figure 1 Sample Coupon Locations

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Figure 2 Side-Bend Testing of HDPE

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15 t 15 t
(150mm min) (150mm min)
1-1/2 t
(25mm
min)
TEST STRAP
BUTT FUSION
15 t 15 t
1-1/2 t
(25mm
min)
TEST STRAP
SOCKET FUSION
15 t 15 t
1-1/2 t
(25mm
min)
TEST STRAP
SADDLE FITTING
Figure 3 Coupon Dimensions

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IMPACT
Clamping
Vice Grips
(typical)
Prepared
Surface
Weld
CL Bead
Flashing
6t (75mm min) 6t (75mm min)

Figure 4 Drop Weight Impact Testing

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AMBIENT TEMPERATURE:
DATE: ________________________________________ _________________
WIND SPEED:
CONTRACTOR: ________________________________ ____________________________
RAIN or SNOW:
FUSION BONDER: ______________________________ ___________________________
FUSION MACHINE TYPE: ________________________ FUSION MACHINE NUMBER:_______________
PRE-PRODUCTION BONDING CHECKLIST:

NOTE: This form shall be completed at the beginning of each fusion bonding production shift.
Item Inspection Procedure Acceptance Criteria Contractor Buyer

Inspector Inspecto
r
1 HEATER PLATE
- thermostat operating, calibrated - calibration records
- plate surface - clean, free from scratches
- plate heating - uniform temp 5.6C
- contact pyrometer calibrated - records
2 HYDRAULICS
- oil reservoir - filled, clean
- pressure gauge operating, calibrated - records (within 3 months)
- hydraulics operating - visual, gauge readings
3 CLAMPS, CUTTERS, ETC.
- clamps, jigs, pullers in good operating - visual
condition
- cutters in good operating condition - visual
4 WEATHER CONDITIONS
- record weather conditions

- above 4.4C (wind chill?) - hoard & heat if < 4.4C
- high wind, rain, snow - protect pipe (hoard)
- pipe temperature - protect pipe against low
temp

Client Name: Sociedad Minera Cerro Verde S.A.A Specification C-CS-50-005
FLUOR
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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 Acceptance Criteria Contractor Buyer

Inspector Inspector
1 TRIAL FUSION
- Visual Examination - visual acceptance criteria

- UT-TOFD examination - UT-TOFD acceptance criteria
2 FUSION BONDING
- record fusion number

- record resin type
- record pipe size & SDR
- record start time
- check heater plate - cleaned
- select heating cycles - per BPS table
- select fusion pres. (with no drag) - per BPS table
- check set up clamps - correct clamps
- pipe ends - square and clean
- check/record drag pressure - calculate total fusion press.
- check pipe ends after facing - aligned with 10% wall thick.
- check/record heater temp. - 10C
- time heater plate removed - per BPS table
- check/record melt bead size - per BPS table
- check/record total fusion pressure - per calculated total fusion in BPS
table
- check bead rollover - complete roll back, uniform
- check/record cooling time - per BPS table
- record finish time

Client Name: Sociedad Minera Cerro Verde S.A.A Specification C-CS-50-005
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FUSION BONDER: _________________________________________ AREA:_____________________ DATE: ______________________
FABRICATOR INSPECTOR:_________________________________ BPS:_____________________ PAGE OF _______
FUSION TYPE: ____________________________________
(SOCKET, BUTT, OR SADDLE FUSION) OWNER INSPECTOR:_____________________________________
FUSION MATERIAL IPS SDR AMBIENT START FINISH FITUP MELT DRAG TOTAL COOL BEAD FAB. OWNER
NO. GRADE RATING TEMP. TIME TIME CHECKED BEAD SIZE PRESSURE FUSION TIME ROLL INSP. INSP.
PRESSURE OVER
FABRICATOR INSPECTOR SIGN. ______________________________________ DATE: ____________________
OWNER INSPECTOR SIGN. ______________________________________ DATE: ____________________
FUSION BONDER SIGN. ______________________________________ DATE: ____________________

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Sociedad Minera Cerro Verde S.A.A.

Primary Sulfide Project

Field Fabrication and Installation

Y:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 HDPE - REV. C.DOC

Rev Originator Rev Revision Description

; New Issue Entire Specification Re-issued

APPROVALS ORIGINAL SIGNED BY

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Y:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 HDPE - REV. C.DOC PIPING

The following specifications describe items of related work:

C. Work Not Included

A. ASME (American Society of Mechanical Engineers)

B31.3 Process Piping

B. ASNT (American Society of Nondestructive Testing)

SNT-TC-1A Recommended Practice for Qualification of Nondestructive

C. ASTM (American Society for Testing and Materials)

Y:\103\109 ENGDOC\109.2 CONSPEC_CS\PIPING\C-CS-50-005\C-CS-50-005 HDPE - REV. C.DOC PIPING

2. D2122 Standard Test Method for Determining Dimensions of Thermoplastic

D. AWS (American Welding Society)

E. NFPA (National Fire Protection Agency)

F. PPI (Plastics Pipe Institute)

B. Bonding Operator See Bonder

C. BPS - Bonding Procedure Specification

D. BPQR Bonding Procedure Qualification Record

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F. Buyer Refer to the Owner of the project or Owners representative

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

P. Sidewall Fusion Bonding See Saddle Fusion Bonding

1.4 Quality Assurance

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1.5 Site Conditions

Refer to Section 1.1 - Related Specifications

2. MATERIALS RECEIVING, INSPECTION, AND STORAGE

2.1 Materials Receiving and Inspection

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4. Absorption of deleterious substances; avoid absorption of liquid hydrocarbons as it could

2.2 Pre- Installation Storage & Exposure to Weather

E. Loose storage stacking height shall be in accordance with manufacturer requirements to

NPS Suggested NPS Suggested

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J. Cold & Hot Weather Handling:

3. FUSION BONDING QUALIFICATION REQUIREMENTS

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3.2 Bonding Procedure Specification (BPS) Requirements

B. Scope of the BPS

C. Dissimilar Fusion Welds

3.3 Bonding Procedure Qualification Record (BPQR) Requirements

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B. BPQR Destructive Testing Requirements

4. EXECUTION OF FIELD FUSION BONDING AND INSTALLATION

4.1 Pipe and Fitting Field Fabrication

C. Bead (Flash) Removal

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F. Pipe Internal Misalignment

4.2 Field Testing, NDE, and Inspection

4.3 Bonding Repair

4.4 Field Installation

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

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,

F. The construction procedures & requirements for underground installation of thermoplastic