Professional Documents
Culture Documents
1 Introduction 1
1.1 Overview 1
1.2 Objectives 1
1.3 Definitions 1
1.4 Communications 1
1.5 Abbreviations 1
2 Scope 3
3 Exclusions 4
4 Referenced Documents 5
4.1 Documents and engineering standards: 5
5 Construction of the HDPE Pipelines for Constancia's Water Systems 6
5.1 General 6
5.2 Access to Site 6
5.3 Transportation, Off-loading, stockpiling, Hauling and storage 6
5.4 Pipeline Routing 6
5.5 Pipeline assembly platforms 6
5.6 Internal pipe cleanliness 8
5.7 Fusion welding 8
5.8 Ultrasonic Examination 8
5.9 Fusion welding inspections and repairs 8
5.10 Pipe installation 8
5.11 Pipe cold bends (field) 9
5.12 Hydrostatic leak testing 9
5.13 Reinstatement activities 10
5.14 Fittings 10
6 Documentation and Deliverables 11
6.1 General 11
6.2 Pipeline construction data 11
6.3 Construction and engineering documentation 11
6.4 Inspection and verification 13
7 Additional Considerations 14
7.1 Project Phases 14
7.2 Special crossings 15
7.3 Workspaces management 16
7.4 Additional provided services 16
1.1 Overview
Ausenco, Process Infrastructure is responsible for the design of the water conveyance,
reclaimed water and seepage systems, property of HudBay Perú SAC, and which EPCM have
been entrusted to Ausenco Perú.
1.2 Objectives
The purpose of this specification is to establish the minimum requirements for the safe and
proper HDPE pipe installation for all the water systems under this scope of work.
1.3 Definitions
In this document:
“Contractor” Refers to the party responsible for the installation of the pipeline
and facilities referenced herein, and appointed by the Company.
1.4 Communications
All formal project communications between Contractor and other parties, including drawings
and procedures, shall be routed through Company. All documentation shall be in English.
1.5 Abbreviations
Table N° 1.1
Abbreviations
Abbreviations Definitions
3D Three-dimensional
Alignment sheet
AS Drawings developed in plant view and side view showing the alignment of
water lines on scale 1:3000 and 1:1,500 vertically.
This specification covers the requirements for the supply of labor, materials, tools and
equipment for the construction and installation of an HDPE Pipeline and other Facilities, at the
Constancia Project.
Contractors shall execute all construction works, which detailed herein, and others that may
be necessary, for the complete and safe installation of the water systems.
Contractors shall have full knowledge of the AWWA M55 Standard (PE Pipe Design and
Installation), as all other standards appointed in this document, and shall comply with all
requirements to the construction and inspection, exception of all of those indicated herein.
Contractor shall include in his scope of work the following specific provisions and activities, for
the completion of his job:
1. Provision of concrete, which will be directly bargained with the Concrete's Subcontractor,
who is formally established by the Company.
2. Fuel shall be within Contractor’s liability. Contractor shall submit in his bid, the rate to be
charge for fuel.
The Quality System shall be designed as to comply with the AWWA M55 Manual, regarding
testing and inspections, special focus on the inspections and qualifications of fusion welders,
records, type of tests and required essays to ensure the quality of the executed works.
The following work is covered by other parties, or will be provided by the Company itself:
1. Fabrication and providing of the HDPE pipes, valves, pumps and barges that will be
installed under this specification.
2. Electrical installations and connections.
3. Instrumentation.
4. Transportation of HDPE pipes, materials and equipment, property of the Company, to
the Central Storage on site.
5. Supply of aggregates, according to specifications on typical drawings for sand bed
(apply to buried pipes), access roads, earthen berms, among others.
6. Campsite, dining, housekeeping, laundry and catering, for all personnel assigned to the
project and according to contract conditions (see Part 2, Section 2 and 3 of ITT).
7. Pre-commissioning, commissioning and start-up, which will be under Company's
responsibility, however, these activities could require of the Contractor's assistance.
See item 7.4.
The Contractor is required to have full knowledge of applicable codes, standards, manuals
and technical specifications listed below, and all other standards included in the technical
drawings and attached documentation, as well as applicable standards for construction of the
Water Systems:
Table N° 4.1
International Codes and Standards referred
Standard / International Organization Description
AWWA Manual M55
PE Pipe – Design and Installation.
American Water Works Association
ASME B31.3 - 2010
Process Piping
The American Society of Mechanical Engineers
ASTM D 1248
Polyethylene plastics molding and extrusion materials
The American Society for Testing and Materials
ASTM D 2321 Standard Practice for Underground Installation of
The American Society for Testing and Materials Flexible Thermoplastic Sewer Pipe.
Standard Practice for Field Leak Testing of
ASTM F2164 - 13 Polyethylene (PE) and Crosslinked Polyethylene
The American Society for Testing and Materials (PEX) Pressure Piping Systems Using Hydrostatic
Pressure
ASTM F2620 – 12 Standard Practice for Heat Fusion Joining of
The American Society for Testing and Materials Polyethylene Pipe and Fittings
OSHAS 18001:2007
Occupational Health and Safety Assessment Series
British Standard Institution
ISO 14001:2004 Environmental Management Systems -Requirements
International Organization for Standardization with Guidance for Use
ISO 9001:2008
Quality Management Systems – Requirements (QMS)
International Organization for Standardization
The scope of work, for the water systems pipeline installation is defined in the following
sections within the ITT (Invitation to Tender):
5.1 General
The Contractor is responsible for the integrity of the pipeline and facilities within Contractor’s
scope of work. As required by the Company, the Contractor shall prepare and submit
procedures, method statements, and risk assessments for each construction activity, the
purpose of which is to ensure all work is performed in a safe manner and in accordance with
this specification.
Prior the start of any field works, the Contractor shall prove that all management system are in
place and are functional. The management systems are defined as systems that are
implemented to ensure the requirements set by the Company. Requirements include but are
not limited to HSEC, Planning & Scheduling, Authority Permits, Quality Control, among others.
Access to site will not be allowable to the Contractor, until the Company submits a written
approval.
Prior to receiving materials, the Contractor shall submit procedures for transportation, off-
loading, stockpiling, hauling, storage and stringing of HDPE pipelines. The Contractor shall be
responsible, after the materials reception, for the loading, off-loading, stockpiling, hauling and
stringing of all materials, including materials supplied by the Company.
Prior to construction, the Contractor shall be responsible for locating and marking the precise
location of existing above and below ground utilities such as pipelines, telephone cables,
electric power cables, etc., that are in close proximity to the proposed pipeline systems.
Contractor shall notify and coordinate this work with the Company. Contractor shall bear the
full cost and responsibility for any damages to these goods of third parties, caused by
Contractor, including any losses from service interruption or loss of product.
The designed layouts for the pipelines of all water systems are shown on the alignment
sheets. See item 4.1.
Contractor shall submit a procedure and a method statement to describe platform opening,
grading activities, platform maintenance works, etc. Submittal will be approved by the
Company.
Due the operational requirements of the Project, it is necessary that the pipeline must be
installed in such a manner as to permit the regular traffic in those sectors where the pipeline
and the different mining roads, share the assembly platform. See typical drawing 2172-5550-
P-003.
In sectors where the pipeline is to be installed over natural ground, the installation platform
shall be defined as it is shown on the typical drawings 2172-5550-P-002. For further details,
see item 5.5.1.
Contractor shall take all the necessary measures as to preserve the platform in good
conditions, and if it's required, water tanker will be used during the dry station, to prevent
excessive dust in the work area.
The Contractor will have the responsibility and the obligation to provide all the required signals
and safety mechanisms (signs, beacons, safety cones, danger stripes, personnel, among
others) in accordance with the project HSEC standards when works are performed on the
installation platform, haul roads, mining access roads or any pipe installation platform so as to
prevent accidents and since the platforms will usually be shared with third parties for the
execution of other works.
Clearing and grading apply to the installation on natural ground, where soil movement shall be
necessary, to open the installation platform.
The Contractor shall remove all trees, trunks, roots, stones and other debris on the clearing
area, and shall carry them into a dump authorized area, according to Company's instructions.
Before commencing with the ground levelling, the Contractor shall submit a procedure, a
method statement and a risk assessment for these activities, for Company's approval.
In areas of rock it shall be necessary to identify whether the substrate material is:
Also the control and management of water runoff in the working area shall be under
Contractor's responsibility and at his sole cost. Runoff management shall be performed in
order to avoid sedimentation of surrounding water courses.
The topsoil stripping will remove the totality of the existing topsoil or until 300mm. The topsoil
piles will be aligned along the lower edge of the platform in piles not higher than 1.50 m,
protected from runoff with silt fences or similar barriers. No equipment or vehicles are allowed
to transit over the topsoil piles. Gaps between topsoil piles will be defined where required for
transit. No material other than topsoil could be dump over the topsoil piles.
The Contractor shall level the installation platform after the stripping of the topsoil in such a
way that the pipeline work can be carried out. Temporal erosion control devices shall be
installed, such as: silt fences, slope breakers, runoff channels, slope coverage, soil bags, geo-
mesh, etc., in order to maintain the stability of the platforms and avoid erosion and
sedimentation of water courses.
The Contractor shall limit levelling of the construction zone, to the minimum required for the
pipeline assembling and shall not exceed the width of the easement provided without written
authorization of the Company.
All temporal access required and which will not been left for maintenance process according to
Company's instructions, will be reinstated to their original condition as soon as the pipeline
installation is completed. Therefore, all topsoil as native soils shall be properly segregated and
handled during access road construction.
The Contractor shall take all necessary precautions to keep the inside of the pipe free of dirt,
waste and other foreign matter. Before coupling and welding, each length of pipe or bend shall
be visually inspected and if necessary, cleaned inside as directed by the Company. Water
used for pipe cleaning will be disposed as state by the Company and only after the inspection
and authorization of the Company.
Whenever internal contamination of the pipe is possible, pipe caps of a type approved by the
Company shall be installed at each open end of all pipe sections to prevent dirt, water,
animals and any other foreign substances from entering the pipe. These caps shall remain in
place until just before the pipe is assembled and welded. Installation and removal of these
caps shall be done in a manner that does no damage to the pipe.
Contractor shall be fully responsible for the proper handling and storage of the pipe.
Ultrasonic Time of Flight Diffraction (UT-TOFD) examination and evaluation of indications shall
be performed by the Contractor.
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 by the Company.
Contractor shall have the duty to submit for approval of Company, a written procedure and a
method statement of the pipe line installation, both on existing roads, and on natural ground
areas.
For installations on existing access roads, the pipe shall always be protected within the berm,
according to drawing 2172-5550-P-003.
When two water pipeline systems are to be installed in the same access road, the two pipes
will be hosted within the berm, considering a minimum clearance distance between its centres
of 1meter (see drawing 2172-5550-P-002).
Water systems will be installed on the opposite side of the channel, when this exists, unless
design drawings indicates otherwise, in which case Contractor shall verify the pipeline
installation position at field and according to Company approval.
The material coming from the berm, will be temporarily stockpiled over the platform, when the
width of the road can allow the regular traffic circulation, otherwise material shall be removed
to specific areas, out of the platform, to allow the vehicular circulation.
For pipe assembly on natural ground, pipeline installation shall comply with typical drawing
2172-5550-P-002.
Same installation conditions will be used for the pipe protection, sheltered within the berm, and
considering the pipe location at the cutting side of the platform as it is shown on the typical
drawing.
As additional considerations, in natural ground installation, where the longitudinal slope of the
installation platform will be greater or equal than 15%, or in natural water courses, low water
crossings shall be constructed as to drain the water through this structure up to the stone
lining that will draw out the water of the platform. The distance between low water crossings is
indicated in the typical drawing.
Special crossings, includes also special installation, which refers to crossings on roads,
channels and swamp areas. For further details, see item 7.2.
The radius of bends shall be, as per AWWA M55. See Table N° 6.1.
Table N° 6.1
Minimum cold (field) bending radius (long term)
Contractor shall submit a procedure and a method statement for pipeline hydraulic test.
Submittal will be subject to approval by the Company.
Reinstatement activities shall apply to all natural ground area, affected by the Contractor,
which will be used by him during the construction process, as stockpiles, temporal yards,
installation platform, extra work spaces, and temporary dump areas for the excavated
material, among others. Do not apply to those installation platform sections, where Company
appointed as maintenance roads.
Prior to the reinstatement activities, Contractor shall prepare procedures and method
statements for reinstatement activities based on the requirements of the Company, unless for.
Reinstatement of the original condition of the surface shall also be understood to include
reinstatement of the original landscape and composition of the soil. It may therefore be
necessary for the Contractor at his own expense to deposit additional topsoil on the platform.
After the topsoil has been spread back over the right of way any stones or rocks with a
diameter larger than 63 mm shall be removed and hauled away.
The various excavated soil layers shall be stored separately and reinstated as they were
originally found. All mixing and contamination shall be avoided.
In sections where terrain and soil conditions are such that pipeline construction has caused a
disturbance to the natural flow of water which may result in platform being washed away, the
Contractor shall take the appropriate measures to prevent such washing away.
The Contractor shall take appropriate measures to ensure the natural flow of water is not
disturbed and does not encroach upon the reinstated pipeline trench.
5.14 Fittings
Contractor shall install and test all fittings within his scope of work, as it is shown on the
mechanical design drawings. Installation and tests shall follow the supplier instructions, when
apply. See specification 2172-3000-ES-601.
6.1 General
Contractor shall perform an As-Built Survey of the new pipeline and its facilities. Survey
documentation shall reference location coordinates by means of GPS equipment or Standard
Electronic Total Stations.
As-Built drawings shall indicate the exact positions, dimensions, route profiles, soil conditions,
environmental details, drainage, stabilization, crossing details and condition of the pipeline and
facilities as required by the Company.
Contractor shall compile comprehensive as-built documentation that includes all construction
and inspection records, material certificates, welding inspection reports, and other pertinent
technical documents. This documentation shall be indexed and placed in hardcover binders.
The format of this documentation is to be approved by the Company. Contractor shall provide
daily updates to this documentation.
Survey teams will record on the top surface of the pipe the following pipeline construction
data, referenced to station identification markings:
Other relevant data (such as specific of the fusion of the joint as indicated on specification
2172-5550-ES-0651).
All calculations, sketches, drawings, tracings and specifications including those from Vendors,
shall be revised to conform to the “As-Built” details and delivered to Company.
Contractor shall establish a fully functional Document Control Department that shall manage
all drawing and document distribution between:
The document control system shall be considered a primary group and shall be audited
periodically by the own Contractor and the Company to assure a high standard of traceability
between documentation is clearly evident.
The Contractor’s construction engineering scope of works shall include, but not be limited to
the review, and further development of the Company’s design, and the preparation of the
following:
The Contractor’s standards may be used with the approval of the Company to simplify
procedures and assist in expediting the project.
Document and drawing numbers shall be assigned in accordance with Contractor’s numbering
system as approved by the Company.
The Contractor shall maintain a master set of as-built red-line markups for the pipeline
throughout all phases of construction. All engineering features shall be located and recorded
on these masters.
Within two months of mechanical completion of the pipeline, Contractor shall submit to the
Company for final approval two (2) sets of as-built drawings depicting the details of the
pipeline and its facilities as they were actually constructed. These markups shall be stamped
and signed off as official documents.
Review and/or formal approval by the Company shall be including all documents/drawings
prepared by the Contractor.
The Contractor shall be responsible for the inspection and testing of all materials required for
the pipeline and its facilities.
Within ninety (90) calendar days of contract award, Contractor shall prepare and submit for
Company Approval a materials testing and inspection program for all relevant materials.
Fourteen (14) calendar days prior to any materials test, the Contractor shall notify the
Company of the planned test date, time and location.
The Contractor shall allow the Company to witness any and all testing activities. However, the
Company will not be obligated to witness any test.
Unless otherwise noted in the codes and specifications, destructive mechanical tests shall not
be required for examining production fusion bonds; except at the request of the Company to
verify fusion weld quality.
7.1.1 General
Construction Completion signifies the end of all construction installation activities, whereas
Mechanical Completion signifies the pipeline and its facilities have been installed, thoroughly
inspected, reworked (if necessary), documented, and the system is ready for Startup.
Mechanical Completion therefore indicates a higher level of readiness for production. The
Contractor is responsible for Construction Completion and Mechanical Completion, and must
provide proof in a controlled and fully documented manner that Mechanical Completion has
been achieved.
The Contractor shall supply all expertise and materials necessary to perform Mechanical
Completion activities (e.g. proving, testing, rework, etc.) safely and efficiently. Included in this
material requirement is the necessary safety equipment, instrumentation, lubricants,
chemicals, spare parts, etc.
Construction Completion shall be declared when the work of installing the pipeline and its
facilities is finished. The next phase leading to Mechanical Completion will be the inspection,
rework (if necessary), and approval of the completed work and/or rework. This phase shall
include:
Methodical, documented checks of each system and subsystem carried out by the
disciplines involved in the construction installation, i.e. Piping, Mechanical, Electrical,
Civil, etc. The purpose of these checks is to verify compliance with the project drawings
and specifications.
Mechanical Completion shall be declared when the pipeline and its facilities have been
inspected, reworked (if necessary), documented, and are ready for Start-up.
The Contractor shall take into account that the work program considers the construction of
water conveyance lines during the rainy season, so the necessary measures shall be included
to comply with the schedule.
The Contractor shall commit to work under quality and HSEC standards of the project, which
include as main and enforceable standard:
For such reason, the Contractor shall specially consider HSEC procedures, the timely
management of permits, the permanent communication with and to the Company and the
Special crossings are defined as untypical pipeline installation sections, originated by pipeline
crossings with existing infrastructure or special natural conditions that require specific
installation characteristics.
Road and channel crossings, will be a below ground installation, as to allow the free vehicular
circulation.
A HDPE corrugated pipe casing will be used under the cross section of the road, as per
indicated on the specified typical drawing.
Road and channel crossings will be a below ground type installation, as to permit the free
vehicular circulation.
A HDPE corrugated pipe casing will be used under the cross section of the road and channel,
as per indicated on the specified typical drawing.
Minimum cover shall comply with the most exigent condition, between the following:
1.0 meter between TOP of pipe and the access road level, or
1.0 meter between TOP of pipe and the bottom of the channel, as shown on the typical
drawing.
The trench for the pipeline installation shall be properly filled and backfilled, according
materials specifications detailed on the corresponding drawing, and according to pipe
installation sequence.
The pipeline bed shall be graded and free of rocks and other objects which could damage the
pipeline. The Contractor shall ensure the bed is constructed to provide a continuous load-
bearing surface for the pipeline.
When the excavated material does not meet the specified requirements for bedding, the
Contractor shall remove such material to a site designated by the Company, and shall supply
suitable replacement material approved by the Company.
For swamp areas, the pipe installation shall consider a special platform treatment, as to allow
a safe vehicular transit, as shown on the specified typical drawing.
Temporal channels will also be subject of special installation. In the event a pipeline shall
cross a temporal channel, without lateral access road, Contractor shall performed all jobs as
indicated on the typical drawing 2172-5550-P-006. Concrete anchor blocks and a wire mesh
shall be installed as defined on the corresponding typical drawing.
The document 2172-5550-LPI-601 contains the list of all crossings and interferences of all
water pipeline systems.
Contractor shall be responsible for the mobilization, installation, maintenance with the
subsequent demobilization of all provisional working platforms and/or site offices, mounted
during the construction work. This includes, among others, provisional offices, equipment
stores, safety fences, chemical toilets, waste water disposal, waste disposal, fuel and other
hazardous materials store, yards, storages, workshops or others required by the Contractor,
unless otherwise specified in the contract. (See Part 2, Sections 2 and 3 of ITT).
The Company could request the Contractor to supply lifting equipment including its operators
(cranes, fork lift cranes, etc.) that may be required by other contractors of complementary
works to the system (installation of pumps and barges). The Company must notify the
Contractor at least 14 calendar days.
Also Company can have the faculty to request the Contractor the provision of trained and
qualified personnel for the pre-commissioning and commissioning, as well as the necessary
equipment for these services. Contractor shall include in his bid the costs of a typical crew to
meet such requirements.