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TEP-SM-0010-PR-QC-1023

PROJECT: TOROMOCHO CC-101 EXPANSION EARTH AND CONCRETE

MOVEMENT

CONTRACTOR DATA
Prepared by: Reviewed by: Approved by: Authorized by:
Name(s): Name(s): Name(s): Name(s):

Position(s): Position(s): Position(s): Position(s):

Head of Mechanical QA/QC Manager Construction Project Manager
Area Manager

Signature(s): Signature(s): Signature(s): Signature(s):

INDEX OF REVISIONS
Version Review Date Description
TO 04.06.18 Issued for internal review SM
B 06.06.18 Issued for SMI review and approval
C 23.09.17 Issued for SMI review and approval

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INDEX
1 OBJECTIVE ………………………………………………………………………...……………………. 4
2 SCOPE ……………………………………………………………………………………………. 4
3 REFERENCE DOCUMENTS …………………………………………….……….…………. 4
4 DEFINITIONS …………………………………………..……………………………….………….… 5
4.1 HDPE pipe
4.2 Butt Fusion Welding
4.3 Equipment operability
4.4 Polyethylene
5 RESPONSIBILITIES……………………………….…………………………………………………..5
5.1 Project Manager
5.2 Head of Production
5.3 SSOMA Chief/Supervisor
5.4 Quality Manager
5.5 Quality Supervisor
5.6 Head of Technical Office
5.7 Front Chief
5.8 Construction Supervisor
5.9 Foreman
5.10 Workers and Officers
6 DEVELOPMENT …………………………………………………………………… …… 9
6.1 Basic concepts
6.1.1 Thermoplastic material
6.1.2 Polyethylene
6.1.3 Classification of HDPE Pipes
6.1.4 Pipe welding by thermofusion
6.2 Hot-melt welding equipment for HDPE pipes
6.2.1 Heating element
6.2.2 Countersignature
6.2.3 Binding mechanism
6.3 Hot-melt welding process for HDPE pipe
6.3.1 Pipe placement
6.3.2 Presentation
6.3.3 Facing
6.3.4 Fusion and joining of ends
6.3.5 Cooling
6.4 Parameters of thermofusion welding for HDPE pipes
6.4.1 Surface Temperature
6.4.2 Facing Pressure
6.4.3 Heating Pressure
6.4.4 Union Pressure

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6.4.5 Warm-up time
6.4.6 Cooling Time
6.4.7 Essential Variables according to Diameter and SDR

7 MODES OF ACCEPTANCE ……………………………………………………………………19

7.1 Welding Quality Control
7.1.1 Quality control during the process
7.1.1.1 Visual Inspection
7.1.2 Master Destructive Testing
7.1.2.1 Tensile test
7.1.2.2 Bending Test
7.1.2.2 Pipe Storage
8 ANNEXES…………………………………………………………………………………………24
8.1 CM121701.QCA.FOR.064 Visual Inspection of Hot Melt Welding
8.2 CM121701.QCA.FOR.065 Field Bending Test Protocols.
8.3 CM121701.QCA.FOR.045 Hydrostatic Test Protocols.
8.4 CM121701.QCA.FOR.066 Welding Specification No. 01.
8.5 CM121701.QCA.FOR.072 Welding Specification No. 02.
8.6 CM121701.QCA.FOR.073 Welding Specification No. 03.
8.7 Liquid in Glass Thermometer Certificate
8.8 Infrared Thermometer Certificate
8.9 Caliper Certificate

1 OBJECTIVE

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Establish the general specific criteria for fusing and/or joining HDPE pipes
using a thermofusion machine and thus successfully achieve the continuity of
the line, taking into account the relevant Technical Specifications.
Establish reliable installation methods and system designs for satisfactory
product and material performance. Any improperly or inappropriately made
joint or connection could cause delays in installation, could disable or impair
system operations, or could create hazardous conditions.

2 SCOPE
The scope of this procedure is directed to all work to be carried out in HDPE
pipe thermofusion.

3 REFERENCE DOCUMENTS

3.1 ASTM STANDARD (AMERICAN STANDARD FOR TESTING

MATERIALS)
ASTM F-714: Standard Specification for Naming Polyethylene Pipe with
SDR-PR Based on Outside Diameter.
ASTM D-1248: Standard Specification for Polyethylene Forming and
Extrusion Materials.
ASTM D-3350: Standard Specification for Polyethylene Pipe and Fitting
Materials.
ASTM D-3035: Standard Specification for Polyethylene Pipe with SDR-PR,
Based on Outside Diameter Control.
ASTM D-2657: Thermofusion Joints for Polyolefin Pipe and Fittings

3.2 AWWA STANDARD (AMERICAN WORK WATER ASSOCIATION)

C906
Standard Specification for pressure of HDPE pipes for water distribution
from 4” to 63” in diameter.
ASME SECTION IX: Boiler and Pressure Vessel Code an International
Code

3.3 PLANS PROVIDED BY MCP.

2110-DW-P-031_B 8011-DW-P-002_2
2110-DW-P-032-0 2115-DW-P-030_0
2110-GA-P-001_1 2115_GA-P-021_1
2115-DW-P-025_0

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4 DEFINITIONS
4.1 HDPE pipe
It is a high-density polyethylene pipe, of variable diameter and thickness,
used to channel or transport liquids.

4.2 Butt welding

It is a welding method for joining polyethylene pipes and their accessories.
The areas of the parts to be joined are heated to the melting temperature and
joined by applying pressure, with mechanical or hydraulic action, according to
the size of the pipe and without using additional joining elements.

4.3 Equipment operability

Verification of the precision status of each instrument or equipment to be
used in the work.

4.4 Polyethylene
Thermoplastic material obtained from the polymerization of ethylene. Four
grades of this material are distinguished according to their molecular weight:

4.5 Hydrostatic Test

It consists of subjecting the line or sections of line to pressures that exceed
the operating pressure for a certain time, normally taken at 1 ½ times the
operating pressure for a period of three hours.

5. RESPONSIBILITIES

5.1 Project Manager

 Lead SMCGSA's safety, occupational health and environmental program on
the project, promoting a safety culture of prevention and participation in all
activities, including subcontractor activities.
 Enforce the activities outlined in this procedure and ensure that it is in the
field.
 Be responsible for ensuring that the stipulated controls are carried out and
that their records are correct.
 Enable and provide those responsible with the equipment and material
resources required to ensure proper supply.

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 Support and adopt the directives and recommendations proposed by the
SMCGSA Management, in order to guarantee the safety and health of
employees in the work to be performed.
 Lead the implementation of procedures that ensure a commitment to safety
and the environment in the area of influence.

5.2 Head of Production.

 Plan the sequence of execution of activities jointly with the Security area,
and inform security if there is any impediment that may jeopardize the
execution of the tasks.
 Enforce the activities outlined in this document.
 Identify and assess the risks of the work to be performed and coordinate
the corrective actions necessary to mitigate them with the advice of the
safety supervisor.
 Stop activities when unsafe working conditions that generate a potential risk
are identified.
 Control and verify that all safety management documents are in the field.
 Control and verify that all workers involved in the activities have the
corresponding PPE
 Verify and control the dissemination of the procedure.
 Daily coordination with field supervision on the activities to be carried out.

5.3 Security Chief/Supervisor

 Verify and supervise the implementation of this procedure in all activities
generated by the work being carried out.
 Be present at all high-risk activities.
 Ensure that management documents and permits are carried out in all
activities and are located in the work area.
 Stop work in operation when working conditions become dangerous and
there is potential risk, until they are minimized.
 Verify that the instructions recommended in this Procedure are followed.
 Control and verify that all workers involved in the activities have the
corresponding PPE
 Check the work area and designate the necessary and appropriate
equipment for the activity to be performed.
 Provide training in the work procedure.

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 Ensure compliance with this procedure and support in meeting the needs
for materials, equipment and human resources, and the execution and/or
inspection of all related work.
 Identify and evaluate the risks of the work to be performed and take the
necessary corrective actions to control them.

5.4 Quality Manager

 Have the Quality Supervisor review this Procedure for the Installation and
Thermofusion of HDPE Pipes, complete the sections referring to quality,
such as applicable inspections and tests; approve this Procedure by the
Quality Management area and submit it to the Project Manager.
 Request documentation relating to pipe installation work from the Head of
the Technical Office and provide it to the Quality Supervisor.
 Have the Quality Supervisors of each discipline review each Procedure and
approve them.
 Disseminate the procedure to personnel involved in the activity.

5.5 Quality Supervisor

 Carry out quality management on the ground.
 Provide training in quality issues to personnel involved in the work
according to the topics covered.
 Attend and participate in pre-inspections of mechanical equipment upon
receipt at the construction site, jointly with the Construction Supervisor.
 Verify proper compliance with technical specifications, plans and
construction details approved by the Client through field inspections and
verifications, checking proper compliance with the acceptance criteria given
in this procedure.
 Verify that the procedure is in place where the activity will be carried out.

5.6 Head of Technical Office

 Lead the engineering management of the project and work related to this
Procedure.
 Keep updated the documents related to the execution of construction
works.
 Distribute the current documents related to this procedure, involving the
Quality Manager and the Front Manager in receiving them.

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5.7 Front Chief
 Prepare this procedure regarding construction and execution
responsibilities and submit it for approval by the Head of Production.
 Dissemination of this approved procedure to all personnel involved in
construction tasks, including supervisors, foremen, operators and
assistants. Presentation of the Training Record to the Quality Manager.
 Request the plans, technical specifications and other contractual
documentation applicable to carrying out construction tasks in this
procedure from the Technical Office Document Control Officer.
 Call the Quality Supervisor for a prior on-site review, recording construction
details to be applied according to current project plans.
 Have the Mechanical Construction Supervisor jointly verify, with the Quality
Supervisor of the discipline, the mechanical equipment upon receipt before
installation.
 Determination, request and administration of resources necessary for the
execution of the construction work of this procedure.

5.8 Construction Supervisor

 Ensure that documents in current versions are available at construction use
points for all personnel.
 Process work permits for crews on the construction fronts involved in this
procedure.
 Participate in the pre-inspection of materials jointly with the Quality
Supervisor.
 Inform the Front Chief of the resources necessary to carry out construction
work, including tools and equipment, and use them efficiently in the work
involved in this procedure.
 Supervise the construction works involved in this procedure and carry out
construction inspections in accordance with the Inspection and Testing
Plan, checking compliance with the requirements given in the plans,
technical specifications and applicable documents.
 Monitor compliance with risk controls, ensuring safety, occupational health
of personnel and care for the environment as set out in the corresponding
SMCGSA standards.
 Inform the Front Manager of the progress and inspection stations; such as
the certification points for the presence of the Quality Supervisor, or the
stopping points that involve the presence of the Client or the Supervision.

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5.9 Foreman
 Receive construction instructions from the Construction Supervisor
regarding the installation of mechanical equipment; transmit field directives
to workers and helpers and lead operational construction activities on site.
 Fill out and complete the continuous IPERC records in the work team and
process their signature in the work crew.
 Inspect the tools of the work crew personnel, verifying that they are in good
condition and reporting any problems to the Construction Supervisor for any
required actions.
 Timely transmit to the Construction Supervisor the requirements for the
proper performance of construction work.

5.10 Workers and Officers

 Carry out operational work in the field efficiently according to the provisions
given by the Foreman.
 Comply with the provisions and measures to control identified risks.
 Do not participate in work for which you are not qualified.
 The thermofusion operator will carry out the gluing of all the joints;
before carrying out the welding, he will have to go through an
approval process.
 The welder's approval will be carried out in the field, the bending test
will be on site.
 The operator will be in charge of the on-site welding procedure, which
will give us all the parameters to perform the WPS.

6. RESOURCES
6.1 Staff
DESCRIPTION

Project Manager
Head of Production.
Security Chief/Supervisor
Quality Manager
Quality Supervisor
Head of Technical Office

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Front Chief
Construction Supervisor
Foremen
Workers and assistants
Officials
Helpers
Figure 1. Project staff table.

6.2 Personal Protective Equipment

The following PPE will be used:

DESCRIPTION

Safety helmet.
Safety glasses.
Rubber gloves.
Leather Gloves.
Safety shoes.
Safety Harness.
Uniform Pants/shirt (both with reflective tape).
Vest with reflective tape for supervisors.
Dust respirator.
Sun block.
Figure 2. Table of personal protective equipment.

6.3 Equipment / Tools / Materials

The following equipment, tools and materials will be used:

DESCRIPTION

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60 kW Electric Generator

Three-phase electrical extensions

Hot Melt Machine

4” dial pressure gauges (calibrated)

Combination Wrench Set (Different Diameters)

Hand Tools

6 Lb Jump Ropes

Torque wrench with current calibration

Thermometer

Figure 4. Machine and tool equipment considered.

7. PROCEDURE

This document corresponds to the quality control procedure to be carried out in

the welding and testing of high-density polyethylene (HDPE) pipes.
The technical specifications that will be taken into account during the works are
those considered in the description of the respective processes.

In the event of adverse weather conditions, such as thunderstorms, rain,

etc., personnel must take shelter in the designated areas in the
corresponding work area.

The thermofusion machines must be placed on a spill-proof tray, which in

turn serves as a temporary storage point for waste produced by the
thermofusion work. Operating personnel must have appropriate storage
points available at the end of each work day.

The equipment will also be located inside a tent which will be covered
with a fireproof blanket and always in dry places.

For the transportation of the thermofusion machines, a flatbed truck or

4”x4” vans provided for the work area are considered.

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The inspection of the work area will be carried out by the production area
together with advice from the safety area.

Welding work using thermal fusion will be carried out in broad daylight. If
night work is required, it will be coordinated with the respective areas and
adequate lighting (300 lux) will be provided inside the welding tent.

Before starting work, the operator of the thermofusion equipment will

present the daily checklist of the equipment for review and/or comments
by the Supervision.

The heat-sealed tent should not be placed in places where water collects
due to rain. If there is any water leak, the equipment operator will check
the area before starting work, and accordingly corrective measures will be
taken, which may range from placing the spill tray on pallets to relocating
the tent.
7.1 Basic Concepts

7.1.1 Thermoplastic material:

They are straight-chain polymers, with molecules containing thousands of
aligned carbon atoms. For these materials, heating causes softening before
reaching their melting point without altering their molecular structure, that is,
without modifying the properties of the material.
This softening-hardening process can be carried out repeatedly. Without
alteration of its properties.
It is precisely this property that is exploited in hot fusion welding.
Polyethylene is one of the most representative materials of this group and lends
itself conveniently to joining by this method.

7.1.2 Polyethylene

Thermoplastic material obtained from the polymerization of ethylene. Four

grades of this material are distinguished according to their molecular weight:

Average molecular weight less than 100,000 carbon atoms

High molecular weight 110,000 to 250,000
Extra high molecular weight 250,000 to 1,500,000
Ultra high molecular weight 1500,000 and up

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The higher the molecular weight, the increased hardness, impact resistance and
abrasion resistance.
Another classification is based on density:

Low density polyethylene  0.93 gr/cc

High density polyethylene  0.93 - 0.96 gr/cc

It is worth mentioning that the higher the density, the higher the tensile strength,
that is, the ability to absorb stress without permanent deformation increases.

Due to its advantageous properties, high-density polyethylene (HDPE) and

extra-high molecular weight polyethylene (EHMW) have been used industrially
as pipe materials to be installed.

In the field, 16” and 10” pipes will be worked on in the first stage.
Continuing with the work, the manufacture of 3”, 6”, 8” and 10” spools will
be carried out. For the transportation of pipes, field personnel are
considered. The quantities will depend on the type of diameter and length
of the spool, and should not exceed 25kg of load capacity per person.

For stacking pipes and spools, it is considered to place 4”x4”x2m long

wooden blocks on the ground and place the pipes and pipe spools on top
of the blocks.

The pipes will be transported in 12m sections using a 12m flatbed truck
with the help of a crane truck. For the transport of spools, field personnel
are considered, the quantity will depend on the fact that the personnel
should not exceed 25kg of load per person.

For the transportation, handling and placement of pipes, it is considered

that they will be secured by personnel at both ends.

7.1.3 Classification of HDPE pipes

These pipes are classified according to a parameter known as SDR which is

defined as the ratio between the controlled pipe outer diameter and the pipe wall
thickness.

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OD= Controlled outer diameter of pipe

t = Wall thickness.

The standardized SDRs are as follows: 41, 32.5, 26, 21, 17, 13.5, 11, 9, 7.3.
Each SDR corresponds to a specific operating pressure.

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The working pressure according to ASTM F-174: 2012 is 200 PSI

The Working Pressure for the HDPE lines of the project according to
Specification 0010-GD-P-007 are:

 16”-FWU-210-4395-P12 = 150 PSI

 10”-FWU-210-4395-P12 = 150 PSI

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The Test Pressure will be the Working Pressure x 1.5 according to standard
B31.3:

 10”-FWU-210-4395-P12 = 150 PSI X 1.5 = 225 PSI

 10”-FWU-210-4395-P12 = 150 PSI X 1.5 = 225 PSI

7.1.4 Pipe welding by thermofusion.

Welding of thermoplastic pipes by fusion of ends, via a conductive heating

element and joining at predetermined pressures.

Before starting the welding process, a microclimate must be set up,

which will consist of an airtight tent to prevent strong winds from
entering and also a reflector for the correct visual inspection test and
parameter verification.
Please note that the temperature should not drop more than 5°C to
weld these pipes. Likewise, when welding, it will be taken into
account to cover the ends of the pipes so that there is no exposure
to dust and wind.
The pipe section must be placed on the same axis as the presses of
the thermofusion machine, for this purpose the placement of
40cmx40cm wooden blocks is considered.

7.2 Hot-melt welding equipment for HDPE pipes.

The brand of the machine to be used is: SUDA PLASTIC PIPE WELDING
MACHINERY CO. LTDA, the model is SUD-IV Series, the product name
is: HYDRAULIC BUTT FUSION WELDING MACHINE.
The latest special machines designed for this use are made up of the
following elements.
These machines will be connected to the 60kw electric generator, which
will have the controls required by the maintenance area such as:
grounding, spill tray, inspected cables, check list of the equipment and
the electrical panel for energy distribution, etc.

7.2.1 Heating element:

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Metal heating plate based on an internal electrical resistance. The metal of
the plate is light (Al) for easy handling and has a thin asbestos cover to
prevent adhesion of the plastic material.

7.2.2 Facing machine:

Rotating disk provided with blades that carries out the chip removal
operation in order to uniform the surface of the faces to be joined and
achieve total contact between them.

7.2.3 6.2.3.- Joining mechanism:

Mechanical or hydraulic system whose function is to put the pipe in contact
with an d /or separate it successively with the heating element, the brazing
tool and the ends of the molten pipe.
In modern machines, this mechanism consists of an Oleo-Hydraulic circuit
that activates a double-acting cylinder to which mobile jaws are attached
that bring the pipes closer or separate them according to the requirement,
at the regulated pressure.

7.3 Hot-melt welding process for HDPE pipes.

This process consists of the following steps:

7.3.1 Pipe placement:

The pipes are placed in the welding machine ensuring a proper fit until the
pipes are perfectly aligned.

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7.3.2 Presentation:
Once the pipe is placed, it is presented at the ends to verify the following
conditions:

 Perpendicularity of the faces with the axis of the pipes.

 Contact of the end faces (must be total)
 Alignment (Misalignment tolerance for KWH pipes is 10% of the
minimum pipe thickness or SDR)
 In this step, the drag pressure must be adjusted, which is the force
required to move the tube, mounted on the machine.

7.3.3 Facing:
 The facing machine is placed between the two ends of the pipes.
 They join together with the help of the binding mechanism.
 The facing machine is activated, which must remove the necessary
material until total contact is achieved between the faces.
 Once the previous condition has been verified, the endorser is removed.

7.3.4 Fusion and Union of Extremes:

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 Once the energized iron has reached the recommended temperature
(KWH 425°F +/- 25°F) it is placed between the ends after cleaning it with
alcohol and an industrial cloth.
 The pipes are put in contact with the plate at a certain pressure.
 Heat until a sufficient bead thickness is formed on both pipes (See table
in 6.4 a)
 The pipes are separated to remove the plate.
 They are quickly brought together, but without violently striking them, the
ends melted at the Interfacial Fusion Pressure (75 PSI).
 After removing the heating plate, the sides should not be separated
for more than 10 seconds.

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7.3.5 Cooling:

The jaws are brought together and allowed to cool for the necessary time until
the material reaches room temperature. This time can be estimated at
approximately 25 minutes per inch of pipe thickness.

Once this step is completed, the clamps are loosened and the pipes are
moved, leaving the last end of the pipe at the height of the machine and
placing the next one, to restart the cycle.

Of all the steps mentioned, the following are considered to be phases of the
process subject to control:

 Alignment
 Facing
 Fusion of extremes
 Union of extremes
 Cooling

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7.4 PARAMETERS OF THERMOMUSSION WELDING FOR HDPE PIPES

To verify the parameters, it will be necessary to take into account the

ambient temperature, relative humidity (See Annex 05), measurement of
the plate with the pyrometer (See Annex 06), verification of the height with
the Bridge Cam and width of the cord with the Caliper (See Annex 07).

The Welding Procedure Specification is also attached to verify all the

parameters indicated below:

 Surface temperature of iron: Measuring instrument PYROMETER

 Endorsement Pressure: Welding Procedure Specification (See Annex
04)
 Fusion Pressure: Welding Procedure Specification (See Annex 04)
 Joint Pressure: Welding Procedure Specification (See Annex 04)
 Cooling Time: Welding Procedure Specification (See Annex 04)

The parameters stated above are not fixed, they vary according to the thickness
of the pipe (SDR), the diameter of the pipe and the temperature of the medium.
Although there are some general recommendations on some reference values.

7.4.1 Surface Temperature

The temperature value recommended by the manufacturer varies between
400ºF - 450ºF. Values close to the lower limit, for small diameter pipes, due to

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the ease of controlling the thickness of the bead, and values close to the upper
limit for pipes with larger diameters, in order to accelerate fusion. (KWH
indicates 425°F +/- 25°F)

7.4.2 Facing pressure.- Manufacturers recommend that the value of this

parameter be between 50 - 85 psi.

7.4.3 Heating Pressure. - This pressure is kept slightly at zero PSI and is
controlled by the geometry of the rod that is being formed, as the material
is heated.

7.4.4 Union Pressure. - Pressure values are variable and dependent on the
diameter and thickness (SDR) of the pipe. The manufacturer has prepared
tables with some values resulting from some tests with its material. These
values are for reference only as significant variations have been observed
from one manufacturer to another.

PRESSURE IN MANOMETER FOR INTERFACIAL FUSION (PM):

(OD2 – ID2) X FI X Pi
PM = ---------------------------------- where:
4 X AP

PM: Pressure gauge pressure PSI

OD: External diameter of the tube in Inches
ID : Inner diameter of the tube in Inches
FI : Interfacial Melt Pressure = 75 Psi
Pi : Pi Factor = 3.1416
AP: Piston Area of the Thermofusion Machine in Square Inches.

Example: Mc Elroy 28 Standard = 4.71 in2

Mc Elroy 618 Standard = 11.78 in2

Thermofusion of Accessories (Tees, Elbows, Flanges)

In the case of Thermofusion of PIPE-FITTINGS-ACCESSORIES (Flanges,

TEES and Elbows) the procedure is identical to that of tube to tube, since the

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unions are only allowed of pipe with accessories with the same diameter and
wall thickness, that is, the same SDR.
In the event that any accessory has a variation in diameter or thickness due to
manufacturer specifications, for the heat fusion the pipe with the smallest
diameter and/or thickness will be centered on the pipe with the largest diameter
and/or thickness, trying to ensure that the largest fusion area remains in contact
with each other.

7.4.5 Warm-up time. - According to the manufacturer's recommendations, the

following graph is taken into account:

7.4.6 Cooling Time.- Manufacturers recommend as a practical reference a

cooling time of between 25 to 30 minutes per inch of pipe thickness.
For work at ambient temperatures of 75ºF (24ºC)

7.4.7 Essential Variables according to Diameter and SDR.

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SDR11（ PE80/PE100)
Pressure Pressure≈ Switching Rising Pressure
P2 P2 P2 P2 P2
＝ P1 P drag time time t 4 ＝ P1
Diameter Thickness Surface
Flanging Heating Cooling Mpa(160/2
（ mm ） （ mm ） force (N) t3 (sec) Mpa(250) Mpa(315) Mpa(450) Mpa(630)
height time t2 time t 5 00)
(mm) (sec) (sec) (min)
25 2.3 24.6 0.7 23 ＜ 3 ＜ 5 8 0.01 0.01 0.01 0.01
32 3 41 0.7 30 ＜ 3 ＜ 5 8 0.02 0.02 0.02 0.02
40 3.7 63.3 1 37 ＜ 3 ＜ 5 9 0.04 0.03 0.03 0.02
50 4.6 98.4 1 46 ＜ 3 ＜ 6 9 0.06 0.06 0.05 0.04 0.04
63 5.8 156.3 1 58 ＜ 3 ＜ 6 10 0.1 0.09 0.08 0.06 0.06
75 6.8 218.4 1 68 ＜ 4 ＜ 6 10 0.14 0.12 0.11 0.09 0.08
90 8.2 315.9 1.5 82 ＜ 4 ＜ 7 11 0.21 0.18 0.16 0.13 0.12
110 10 471 1.5 100 ＜ 4 ＜ 7 14 0.31 0.27 0.24 0.19 0.17
125 11.4 610 1.5 114 ＜ 4 ＜ 8 15 0.4 0.35 0.3 0.25 0.23
140 12.7 761.5 2 127 ＜ 4 ＜ 12 17 0.5 0.43 0.38 0.31 0.28
160 14.6 999.9 2 146 ＜ 5 ＜ 13 19 0.65 0.57 0.5 0.4 0.37
180 16.4 1263.7 2 164 ＜ 5 ＜ 14 21 0.83 0.71 0.63 0.51 0.47
200 18.2 1558.4 2 182 ＜ 5 ＜ 15 23 1.02 0.88 0.78 0.63 0.58
225 20.5 1974.5 2.5 205 ＜ 5 ＜ 12 26 1.12 0.99 0.8 0.73
250 22.7 2430.2 2.5 227 ＜ 6 ＜ 13 28 1.37 1.22 0.98 0.9
280 25.4 3045.9 2.5 254 ＜ 6 ＜ 14 31 1.52 1.23 1.12
315 28.6 3858 3 286 ＜ 6 ＜ 15 35 1.93 1.56 1.42
355 32.2 4895.6 3 322 ＜ 7 ＜ 17 39 1.98 1.81
400 36.3 6218.3 3 363 ＜ 7 ＜ 19 44 2.52 2.3
450 40.9 7880.9 3.5 409 ＜ 8 ＜ 21 50 3.19 2.91
500 45.4 9720.9 3.5 454 ＜ 8 ＜ 23 55 3.59
560 50.8 12183.5 4 508 ＜ 9 ＜ 25 61 4.5
630 57.2 15431.9 4 572 ＜ 9 ＜ 29 67 5.7

8. MODES OF ACCEPTANCE

8.1 WELDING QUALITY CONTROL

The quality control program to ensure quality will be done in an indirect way:
- During the welding process of each joint (CM121701.QCA.FOR.064 Visual
Inspection of HDPE Pipe Welding See Annex 01, See Table No. 01).
- Non-destructive testing
- Destructive sample tests, With this test we begin to make the welding joints.
(See Annex 02 for Inspection Form CM121701.QCA.FOR.065 HDPE pipe
field bending test).
- Once the process is completed (Hydrostatic Test and Flushing), the
procedure will be sent with Code Number TEP-SM-0010-PR-QC-043, See
Annex 03 for Inspection Format CM121701.QCA.FOR.045_Hydrostatic
Pipe Test)

8.1.1 QUALITY CONTROL DURING THE PROCESS

8.1.1.1 Visual Inspection

Because the quality of an HDPE weld depends largely on how it has been
worked, in each phase, within the appropriate ranges of pressure, temperature
and time, these parameters will be controlled in the format called WELDING
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PROCEDURES SPECIFICATION, where the recommended values must be
reflected.

The configuration of the board will directly indicate the correctness of the
parameters assigned in the previous control.
The following aspects should be taken into account:
.
Higher pressure than recommended will cause the bead to overlap itself,
which may result in a poor quality fusion as the bead will be expelled to the
outer and inner diameter of the fusion, creating a “cold ring” in the central area
of the fusion.

Lower pressure than recommended will result in inadequate fusion due to

insufficient contact in the melted area.

The formed flange must be uniform in size and shape all around the joint.

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Table No. 01

Good alignment is a basic condition for the pipe to be able to normally withstand
bending stresses in the seam area. The eccentricity must not exceed 10% of the
pipe thickness.

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Important Note.-The control of these details of conformation and assembly

(points 1.2 to 1.3), will be reflected in the VERIFICATION OF WELDING
JOINT format, (CM121701.QCA.FOR.064 Visual Inspection of HDPE Pipe
Welding See Annex 01)

Welding parameters will be carried out at each joint to be welded, with

permanent personnel for each joint.

8.1.1.2 Ultrasound Test: (The procedure was sent with code number
TEP-SM-0010-PR-QC-042)

8.1.2 DESTRUCTIVE SAMPLE TESTING

These tests are performed according to the client's specifications or

specifications, the ASME SECTION IX code standard and the Pipe
Manufacturer's instructions.

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According to the ASME Section IX code, the following tests will be
performed and attached in the Test package:

8.1.2.1 TENSILE TESTS:

A test joint will be made for each type and diameter of pipe from which
three equidistant strips will be removed from the periphery of the seam and
with the following dimensions:

Length equal to 15 times the thickness on each side of the seam and with
a minimum of 6”

Width equal to 1.5 times the thickness and with a minimum of 1”.

2.00 strips of these will be taken and sent to the laboratory for their
respective testing.
Once the test is completed, the welding factor will be calculated according
to the formula:

Sf = Maximum tensile strength of the base material

Maximum tensile strength of the weld bead

The factor must be greater than or equal to 0.8.

8.1.2.2 BEND TEST:

This test will be carried out in the field and at the start of the thermofusion
and/or when requested by the Client's Quality Control Supervisor, and will
consist of the following:

In the test joint, the two remaining strips whose measurements were
defined in the tensile test will be taken and the following procedure will be
followed:
The strips will be bent at 60° +_ 10° taking into account making a fold on
the outside of the strip and the next fold on the inside. (As shown in the
figure).

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After folding, the seams should not have pores, cracks and/or visible
imperfections.

For bending tests of pipe samples with greater thicknesses, a field press
will be used, as shown in the photo:

8.1.2.3 Pipe Storage

Pipe storage will have to be placed on blocks stacked one next to the
other, also one on top of the other with their support blocks so that they do
not slide.

8 ANNEXES

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 Appendix 01: Visual inspection of HDPE welding.

 Annex 02: HDPE pipe field test protocol.
 Annex 03: Hydrostatic test record for pipes.
 Annex 04: Fusion test specification.
 Annex 05: Liquid thermometer calibration certificate.
 Annex 06: Infrared thermometer calibration certificate.
 Annex 07: Caliper calibration certificate.

8.1 Annex 01

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Control y Aseguramiento de Calidad CM121701.QCA.FOR.064

Fecha Versión Pagina

INSPECCION VISUAL DE SOLDADURA TUBERÍA HDPE
5/06/2018 0 1

1.- DA TOS GENER A LES (GENER A L DA TA ):

PROYECTO: EXPANSIÓN TOROMOCHO CC-101 MOVIMIENTO DE TIERRAS Y CONCRETO

SUPERVISIÓ/CLIENTE: FECHA:
AREA: No. DE REGISTRO:
PLANO DE REFERENCIA: ESPECIFICACION DE REFERENCIA:

2.- P UNTOS DE INSP EC C ION (J OINTS A ND P OINTS OF INSP EC TION)

EQUIPO EMPLEADO:

MAQUINA DE FUSIÓN: MODELO: SERIE:

LÍNEA:
PLANO DE REFERENCIA: φ TUBERÍA: SDR:

Item Descripción del CHECK Datos Aceptable No Aceptable

1 El cordon es continuo y de tamaño constante alrededor de toda la circunferencia del tubo.

2 La soldadura HDPE es uniforme.

3 El cordon no debe existir socavaciones en los bordes de la soldadura HDPE.

4 El ancho total del cordon de soldadura de doble fusión debe ser de 2 a 2.5 veces la altura de la soldadura desde la superficie del tubo.

5 No hay presencia de aperturas ni de vacíos visibles entre los cordones del empalme por fusión.

6 No hay desalineamiento en los extremos de los tubos mayores al 10% del espesor del tubo.

7 No hay porosidad en el cordón desoldadura.

Código Tiempo de Temperatura Presión de Tiempo de Resultado de la Inspección

Hora de Hora de Tipo de A DR HR Diametro
Item de junta / TA (C°) FPS SDR Calentamiento de la Plancha Fusión Enfriamiento
Inicio Termino Unión (mm) (mm) (%) (pulg) Aceptado Reparar Defecto
Nodo (min) (°C) (Bar) (min)

LEYENDA : C =CONFORM E (ACCEP TABLE) NC =NO CONFORM E (REJ ECT)

(LEGEND) P A =P OROSIDAD AISLADA (P IP ING P OROSITY) C I =CORDON IRREGULAR (IRREGULAR CORDON)

3.- OB SER VA C IONES (OB SER VA TIONS)

4.- A P R OB A C IÓN FINA L (FINA L A P P R OVA L)

Producción - SMCG Control de Calidad- SMCG Supervisión QA Supervisión/ Cliente

Nombre: Nombre: Nombre: Nombre:

Firma: Firma: Firma: Firma:

Fecha: Fecha: Fecha: Fecha:

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8.2 Annex 02

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Control y Aseguramiento de Calidad CM121701.QCA.FOR.065

Fecha Versión Pagina

PROTOCOLO DE PRUEBA EN CAMPO DE TUBERÍA HDPE
5/06/2018 0

1.- DA TOS GENER A LES (GENER A L DA TA ):

PROYECTO: EXPANSIÓN TOROMOCHO CC-101 MOVIMIENTO DE TIERRAS Y CONCRETO

SUPERVISIÓN/CLIENTE: FECHA:

AREA: N° DE REGISTRO:

PLANO DE REFERENCIA: ESPECIFICACION DE REFERENCIA:

2.- ESQUEMA Y PUNTOS DE INSPECCION (POINTS OF INSPECTION)

DATOS DE CAMPO

Nombre del Operador:

Diámetro: Maquina (Modelo y Serie)

SDR : N° Lote de Tubería

Espesor: Fabricante
Condiciones Ambientales (Temperatura
Longitud de Probeta:
y Humedad)
Ancho de Probeta:

PRUEBA DE DOBLEZ
Probeta A Probeta B
Doblada Doblada
La Junta esta Doblada 60º?

La Junta Resiste el Doblez de Prueba?

La Junta Presenta Vacios o Poros?

La Junta Presenta Areas de No Adherencia?

PARAMETROS

Temperatura de la Plancha

Tiempo de calentamiento

Presión de Fusión

Tiempo de Fusión

Parametros Ambientales

OBSERVACIONES

Producción - SMCG Control de Calidad- SMCG Supervisión QA Supervisión/ Cliente

Nombre: Nombre: Nombre: Nombre:

Firma: Firma: Firma: Firma:

Fecha: Fecha: Fecha: Fecha:

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8.3 Annex 03
Control y Aseguramiento de Calidad CM121701.QCA.FOR.045

Fecha Versión Pagina

REGISTRO DE PRUEBA HIDROSTÁTICA PARA TUBERÍAS
11/04/2018 0

PROYECTO: EXPANSIÓN TOROMOCHO CC-101 MOVIMIENTO DE TIERRAS Y CONCRETO

ÁREA: PLANO O REF:

SISTEMA / FACILITY: Nº REGISTRO:

FECHA:

DESCRIPCIÓN: TAG:

VERIFICACIÓN DE ACTIVIDADES PREVIAS

ITEM TAG LÍNEA Nº PLANO Nº P&ID Nº REGISTRO NOTAS

DATOS DEL INSTRUMENTO DE PRUEBA

Equipo 1 M arca M odelo Nº/S

Rango Fecha de calibracion Nº/ Certif

Equipo 2 M arca M odelo Nº/S

Rango Fecha de calibracion Nº/ Certif

CONDICIONES DE PRUEBA DE PRESIÓN

Fluido de prueba: Presión de diseño: Presión de prueba:
Temperatura: Tiempo de prueba: Otras condiciones:
Norma o estándar de referencia:

DATOS DE PRUEBA HIDROSTÁTICA / NEUMÁTICA

Nº Hora (T) min Temp (ºC) Presión (PSIg)
P
1
2
3
4
5
6
7
8
9
10
T
Presencia de fugas: Si ( ) / No ( ) RESULTADO: conforme ( ) No Conforme ( )

COMENTARIOS / OBSERVACIONES

Producción - SMCG Control de Calidad - SMCG Supervisión QA Supervisión/Cliente

Nombre: Nombre: Nombre: Nombre:

Firma: Firma: Firma: Firma:

Fecha: Fecha: Fecha: Fecha:

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8.4 Annex 04

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8.5 Annex 04

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8.6 Annex 04

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8.7 Annex 05

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8.8 Annex 06

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8.9 Annex 07

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