DVS-xxxxxxxxxxx

Edition: Effective: Page 1 of 10

1 11-July-2019
Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

PREFABRICATION AND INSTALLATION OF

ELECTROFUSION
HDPE PIPES

Identification of Changes
Edition Date Change Page / Numeral
01 11-Jul-2019 Document Creation and Approval NA

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Edition: Effective: Page 2 of 10
1 11-July-2019
Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

1. OBJECTIVE

Establish the activities to be implemented in DVS projects during the prefabrication and installation of pipes HDPE electro
fusion according to the project requirements and those indicated in the ASME BPV Code Section manufacturing I and
Pressure Piping B31.1 and B31 .3 editions and current addendum.

2. SCOPE

This procedure applies to all projects DVS which works prefabrication of HDPE pipe is made by electro fusion workshop,
prefabrication of pipe HDPE electro fusion field and for the installation of piping HDPE electro fusion buried in processing
plants as ASME B31.3 and ASME power plants as B31.1.

3. DEFINITIONS AND ABBREVIATIONS

DVS: CONSTRUCTORA DV SANTOS SA

WPS: Welding procedure specification.

WPQ: Welder performance qualification.

spool: Pipe section configured with accessories is directed to one point to another.

END: Nondestructive examination. It involves inspections required by the applicable Building Code.

ASME: American Society of Mechanical Engineering

AWS: American Welding Society

ELECTROFUSION: Process for welding pipes HDPE .

HSE: Health, Safety and Environmental

4. RESPONSIBILITIES

4.1 Site manager

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Edition: Effective: Page 3 of 10
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Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

 It is responsible for compliance with this document and project specifications to ensure that the works are
executed in accordance with contractual requirements in a safely manner.

 Assigns, reviews and assesses the resources required in the project in order to implement the required
activities.

 Communication Site Manager with the Chief QA / QC and HSE department of the assigned project will be
open, respectful, assertive and confrontational in order to get agree on the best solution to the problem.

4.2 Chief QA / QC Work

 It is responsible for monitoring compliance with this document and project specifications according to plan
inspections and verify that the information required to ensure that the work has been executed in accordance
with contractual requirements.

 Organizes the documentation generated during the work of prefabrication and installation of pipes HDPE
electro fusion within the project and coordinates the delivery to the customer for acceptance of the work
performed.

4.3 HSE Department

  Is responsible for verifying the safety conditions at field according to the established in the work permits and
Job Safety Analysis.

 Participate in the process of planning, verify and audit legal documentation of personnel that is part of the activity
of Prefabrication and Assembly of HDPE pipeline as well as any certification or chemical used for the process.

4.3 Mechanical superintendent

 It is responsible for the implementation of the activities identified in this document and project specifications.

 Plan activities according to the schedule of project progress and timely communicated to the Chief QA / QC
work activities to coordinate the checks required during the implementation of activities.

4.4 Mechanical Works Supervisor

 Executes delegated by the Mechanical Superintendent for prefabrication and assembly of electro fusion
HDPE pipes as specified project activities.

 It controls the progress of activities comply with the schedule of project progress and provides access to the
execution of the trials and tests set out in the project specifications.

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Edition: Effective: Page 4 of 10
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Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

 Tasks and record test results required in the project specifications and the Plan of Inspections and tests (ITP).

 Dispose waste according to the waste management procedure DVS-PS04.PRO-007 and leave the area
safely.

 Responsible for supervising that the activity is carried out safely and in accordance with agreement in
the work permits and risk analysis.
 Verify and give notice of any worker's health problems when they arrive or during the execution of
activities.

5. PROCESS

5.1 General indications

5.1.1 Mechanical Works Supervisor must be familiar with the project scope. For this, the Mechanical
Superintendent provides pertinent information such as project plans and specifications information.

5.1.2 Mechanic Superintendent jobs should plan ahead in order to carry out the work of prefabrication and
installation of HDPE pipes by electrofusion required.

5.1.3 Mechanic Supervisor is responsible for obtaining work permits with the help of HSE Department in the area
where they will perform the prefabricated assembly of pipes and HDPE electro fusion.

5.1.4 The materials used in prefabrication and installation of HDPE pipes by electrofusion prior to installation must
be inspected by the Supervisor QA / QC, in order to verify that meet design specifications. The materials to
be used during installation shall be inspected in accordance with the procedure DVS-PO05-PRO-002
Inspection of materials and equipment Work.

5.1.5 All work involving welding must be performed using a qualified WPS.

5.1.6 Welding operators shall be qualified according to qualified WPS.

5.1.7 Boards are identified by a unique consecutive number for isometric in the flow direction. If any additional
seals to those shown in the drawings, the identification of new boards will be the same of the previous board
consecutively adding a letter below. The brazed joints made during prefabrication will be identified with the
letter S before the consecutive number and the joints made in the field they shall be identified with the
letters F before consecutive number.

5.1.8 Welding work performed daily are recorded by the Supervisor of Mechanical Work in document DVS-POM5-
PRO-010-002 Welding Daily report and reviewed by the Supervisor QA / QC.

5.1.9 The minimum equipment for the implementation of activities will be:

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Edition: Effective: Page 5 of 10
1 11-July-2019
Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

 Truck crane
 Welding machine

5.2 Welding process electro fusión

5.2.1 Perpendicularly cut ends of the tubes to be joined.

5.2.2 Clean the dirt from the ends of the tubes, approximately 500 mm, using a clean paper.
5.2.3 Use the accessory, without removing it from the bag, to mark the minimum length of pipe to be scraped at
each end, (half the length of the sleeve over about 25 mm).

5.2.4 Use a scraper to remove the marked surface layer around the pipe ends to be joined. No use sandpaper or
emery cloth to clean or scrape toward the tube end.

5.2.5 Ensure that has been scraped all marked surface area.

5.2.6 Do not touch with hands scraped areas.

5.2.7 Verify that has been scraped entire surface of the bottom of the tube.

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Edition: Effective: Page 6 of 10
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Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

5.2.8 Remove the sleeve from the bag and read the label to make sure you have chosen the correct measure.

5.2.9 Positioning the cuff on one end of the tube. Mark the penetration depth when the center mark of the sleeve
matches the end of the tube.

5.2.10 Remove the sleeve and insert the end of the other tube. Mark the penetration depth when the center mark
of the sleeve matches the end of the tube.

5.2.11 Place and slightly tighten the aligner.

5.2.12 Place the tube ends within the sleeve.

5.2.13 Ensure that the sleeve is centered on the aligner and the tubes have been introduced to the mark
penetration depth. Fully tighten the aligner.

5.2.14 Rotating the sleeve gently to ensure that the pipes are not misaligned.

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Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

5.2.15 Remove the caps protecting the terminals of the sleeve.

5.2.16 Connecting the cables to the terminals of the sleeve.

5.2.17 See melting time indicated in the attachment and place in the electrofusion welding machine. Vending
machines, passing the stylus or card.

5.2.18 Press the "start" button and make sure the fusion cycle is completed. Process EF welding sleeves.

5.2.19 Without moving the sleeve, allow to cool in the aligner time indicated on the label.

5.2.20 Remove the cables and remove the aligner.

5.2.21 Visually inspect the attachment and check that they have left the melting witnesses.

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Edition: Effective: Page 8 of 10
1 11-July-2019
Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

5.2.22 All weld joint will be visually inspected by the QA / QC Supervisor according to the procedure DVS-PSM3-
PRO-002 Visual examination.

5.2.23 QA / QC Supervisor performs the inspection of prefabricated elements prior to his office at the project site.
The inspection includes verification of shapes, dimensions, materials, identification, visual examination of
welding and non-destructive testing required by the building code.

5.3 Buried pipes

5.3.1 Mechanical Works Supervisor coordinates with the surveyor for the stroke prior to performing the excavation
work axes.

5.3.2 Prior to the excavation, the Supervisor of Mechanical Works investigates the presence of any existing facility
that could be affected by these works.

5.3.3 The dimensions of the trench will be as indicated in the building plans. The deep trenches must be stabilized
to prevent collapse during assembly into the pipes.

5.3.4 It prior to pipe installation, a sand bed is placed, to avoid damage to the pipe coating.

5.3.5 Any activity involving excavation, ditch or dike must comply with the excavation and ditch procedure DVS-
PS04-PRO-027

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Edition: Effective: Page 9 of 10
1 11-July-2019
Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

5.3.6 The coordinates of the pipe are made by the surveyor once the pipe has been installed in the trench.

5.3.7 The pipes are covered when installed with a bed of sand prior to filling with natural soil or imported material.

5.3.8 Where required berths and / or dead concrete for securing buried pipes are installed.

5.3.9 Buried piping installations are recorded by the Supervisor of Mechanical Work in document DVS-POM5-
PRO-010-REG-006 Installation log buried pipe.

6. RECORDS

DVS-POM5-PRO-010-REG-002 Welding Daily Report.

DVS-POM5-PRO-010-REG-006 Installation log buried pipe.

DVS-PS04-PRO-027 Excavation and Ditch Procedure

DVS-PS04.PRO-007 Waste and Disposal Procedure

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Edition: Effective: Page 10 of 10
1 11-July-2019
Prefabrication and Installation of Elaborated: Revised: Approved:

Electrofusion HDPE Pipes

Quality Control Leader COO PMO Manager and

Strategy

7. ATTACHMENTS / REFERENCES

DVS-PO05-PRO-002 Inspection of materials and equipment Work

DVS-PSM3-PRO-002 Visual examination

ASME BPV Section IX

ASME B31.1

ASME B31.3

8. OTHERS

Does not apply

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