000-gc-p-009 r.3 piping installation.pdf

8/11/2019 000-GC-P-009 R.3 Piping Installation.pdf

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PROJECT NO. C-560

MINERA CHINALCO PERU S.A.

TOROMOCHO PROJECT

General Specification 000-GC-P-009

Piping Installation

Aker Solutions Owner Approval: J.F. Wigle

333, E. Wetmore Road, Suite 600Tucson, Arizona 85705-1799 Date: April 2008REV DATE BY CHK APPROVAL DESCRIPTION

A 02/14/08 DC JBS ISSUED FOR INTERNAL REVIEW

B 03/12/08 DC JBS MW ISSUED FOR CLIENT APPROVAL

0 4/01/08 DC JBS AIH ISSUED FOR CONSTRUCTION

1 6/02/09 TG JBS CB / AIH RE-ISSUED FOR CONSTRUCTION DETAIL

ENGINEERING

2 2/03/11 MS APP/JBS PH / RC RE-ISSUED FOR CONSTRUCTION, REVISEDCOLOR CODE TABLE 1A , 1B

3 08/15/11 TG APP RC UPDATED TABLE 1A AS NOTED


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Project No. C-560General Specification 000-GC-P-009

Piping InstallationRev. 3

INDEXPAGE

1 SCOPE 3

2 CODES AND STANDARDS 3

3 PIPING IDENTIFICATION 4

4 GENERAL REQUIREMENTS 5

5

CATHODIC PROTECTION 7

6 PIPE BENDING 7

7 WELDER QUALIFICATION AND PROCEDURE APPROVAL 7

8 FIELD WELDING CARBON STEEL PIPE 8

9 FIELD WELDING ALLOY PIPE 9

10 UNDERGROUND PIPING 10

11 OXYGEN PIPING 12

12

GENERAL PROCEDURES FOR PRESSURE TESTING 21

13 TEMPORARY PIPING 23

14 MECHANICAL CLEANING 23


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1 SCOPE

This General Criteria Specification covers minimum requirements for the installation ofall process and utility piping for the Toromocho Project located in central Peru.

The intent of this specification is to state the basic minimum requirement and standardsthat shall complement the engineering drawings of this project.

2 CODES AND STANDARDS

2.1 Definitions

Owner: Minera Peru Copper S.A.

Buyer/Engineer: Aker Solutions Metals, IncVendor/Contractor: Contractor hired to perform the work and installation.

All material, fabrication, assembly and installation, where applicable, shallconform to the current editions of the following codes and standards:

ANSI American National Standards Institute

A13.1 - Scheme for the Identification of Piping Systems

ASME Codes for Pressure Piping B31

B31.1 - Power Piping (for steam and condensate systems)

B31.3 - Chemical Plant and Petroleum Refinery Piping

(For Process and utility piping within plant boundary limits).

B31.4 - Liquid Petroleum Transportation Piping Systems

(For long distance liquid pipeline work, normally outside plant battery limitboundary).

B31.8 - Gas Transmission and Distribution Piping Systems

(For fuel gas systems outside plant battery limits)

B31 11 Slurry Transportation Piping Systems


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ASTM American Society for Testing and Materials

AWS American Welding Society

AWWA American Water Works Association Inc

CGA Compressed Gas Association

CISPI Cast Iron Soil Pipe Institute

FM Factory Mutual Engineering Division Recommended Practices

IBC International Building Code, 2006

MSHA Mine Safety and Health Administration

NFPA National Fire Protection Association

OSHA Occupational Safety and Health Administration

UBC Uniform Building Code

NTP 399.012 Norma Tcnica Peruana, 1974. (Colores de Identificacin deTuberas Para Trasporte de Fluidos en Estado Gaseoso o Lquidoen Instalaciones Terrestres y en Naves)

DS 046-2001 Reglamento de Seguridad e Higiene Minera, art. 92, 93 yAnexo 11

All applicable Peruvian and Local Laws and Regulations.

In the event of differences between codes and/or standards, the most stringentcode or standard shall apply. Whenever reference is made to a specific code orstandard, it shall be understood that the latest edition of such reference, as ofthe date of proposal, shall govern.


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attached Appendix I of this specification, corresponding to the commodity code shownon the line designation.Labels shall be in Spanish.

4 GENERAL REQUIREMENTS

Piping shall be installed in accordance with all drawings, applicable codes andstandards, and requirements of this specification and attachments. Any deviations fromdrawings, applicable codes and standards, and requirements of this specification mustbe approved in writing by the Buyer.

Critical dimensions shown on drawings, such as face to face of flanges, location ofoutlets, etc., will be limited to a tolerance of plus or minus 3 mm. Vendor shall beresponsible for field verification of all drawings and changes shall be marked up on

drawings and submitted to the Buyer.

Buyerwill issue piping isometric drawings for all areas. Vendor may prepare fabricationisometrics at his discretion to facilitate piping fabrication and installation.

Piping materials and branch reinforcements shall be in accordance with GeneralSpecification 000-GD-P-007, Piping Material Classes. All piping materials whenreceived shall be inspected for handling and transportation damage.

All piping materials including pipes, flanges, gaskets, nuts and bolts shall be new.

All piping work shall be subject to inspection by Buyer at any given time.

Piping joints shall not be covered by insulation before any pressure test.

In-line instruments shall be installed by the piping Vendor.

All pressure relief valves shall be installed in an upright position.

Orifice plates shall be 3 mm thick for line sizes 300 mm NPD and smaller, and 6 mmthick for 350 mm NPD and larger.

Internal burrs and excess weld material shall be removed from the upstream run of allifi l t


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drawings. Vendor may install additional break flanges, unions, or break couplings withprior written approval from the Buyer.Flange bolts shall have their threads lubricated with molybdenum disulfide, or anequivalent lubricant. Lubricant used in piping for oxygen service shall be oxygencompatible.

Bolt holes shall straddle the vertical centerline, or radial centerline, unless shownotherwise on the drawings.Where piping requires welding interface with piping supplied "By Others", the materialsbeing joined shall have weld compatibility. Flanged connections may be used asnecessary.

If welding fittings corresponding to pipe wall thickness are not available, thicker fittingsmay be used with ends taper bored to match the pipe inside diameter.

A swage nipple may be used when a pipe size change is necessary for connecting toequipment or to instruments.

No close nipples shall be used.

Low points in all piping shall be provided with valved drains as indicated on drawings orPiping and Instrumentation Diagrams (P&IDs).

High points in all lines which will be hydrostatically tested shall be provided with a ventfor venting air during filling and be provided with a plug (seal welded if threaded end).

All drains discharging into open funnels shall terminate at 50 mm from the top of thefunnel.

Piping shall be kept clear of manholes, clean-outs, drains, access openings, andinspection points.

Open-end line valves shall be closed either with a plug, nipple and cap, or blind flangewhere indicated on drawings. Closure shall be consistent with the appropriate pipingspecification.

All unused openings in process equipment shall be closed either with a plug, nipple andcap or blind flange nless other ise noted on the dra ings


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Temporary strainers shall be provided where called for in the drawings. No temporarystrainer shall be permanently removed from its hook-up until all internal foreign materialshave been trapped and thoroughly removed from the piping system. Temporarystrainers shall be removed only after the piping system has been accepted by the Buyerand the Owner and prior to placing the piping in normal service. Cone strainers shall beinstalled in spool with flanged ends for ease of removal.

All piping supports shall be designed in accordance with the seismic and windparameters/conditions set forth in Appendix A.

5 CATHODIC PROTECTION

This Section does not apply to the Project.

6 PIPE BENDING

All field-bending of steel piping shall be limited to 150 mm and smaller pipe and subjectto approval by the Buyer.

All pipe bends shall be true to angle with a minimum tangent of 150 mm on both ends.

6.1 Underground Water Steel Pipeline

This Section does not apply to the Project.

6.2 Underground Non Steel Pipeline

Bending of plastic piping shall be governed by the pipe manufacturersrecommendations.

7 WELDER QUALIFICATION AND PROCEDURE APPROVAL

Welding operators shall be pre-qualified to ensure that welds will meet the requirementsof this specification. All tests shall be in strict accordance with the provisions of Section


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8 FIELD WELDING CARBON STEEL PIPE

The ends of pipe and welding fittings shall be beveled in accordance with the ASMEB16.25. Preparation of ends by machining is preferred. Fusion and penetration shallbe obtained without "icicles" or drip through at the root.

Alignment of pipe and fittings shall be maintained during the welding process. Tackwelds shall be removed by chipping or grinding and care shall be taken to insure thatthe first bead completely fuses through the tack welds. Tack welds incorporated into theroot pass shall be welded by qualified welders. All cracked tack welds shall beremoved.

Faces of all flanges shall be at exactly 90 degrees to the longitudinal axis of the pipe.

Welding back-up rings shall not be used.

Fabricated pieces with ends marked for field welding shall be counter-bored to thenominal inside pipe diameter for accurate internal fit-up.

Finished wall thickness shall not be less than the minimum design thickness pluscorrosion and erosion allowance.

All welding shall be done by manual metal arc process, automatic submerged arcprocess, metal inert gas process (MIG), tungsten inert gas process (TIG), or acombination of them. The root pass on all welded pipes for oxygen service shall bemade by tungsten inert gas (TIG) process. Other welding processes are prohibited.

Double welded butt joints shall have the back or second side chipped, air arced orground to sound, clean metal before depositing weld metal on that side.

Welding electrodes for manual metal arc welding for steel shall be heavily coated and

shall conform to ASTM A-233 material specifications. The chemical composition andphysical properties of the deposited metal shall be similar to that of the base material.

Filler electrodes and the fluxes used with the automatic submerged arc process shalldeposit weld metal of chemical composition and physical properties compatible with thebase metal.


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Direct current, with reverse polarity shall be used for all manual electric arc welding,automatic submerged arc welding, and MIG welding.

Direct current, with straight polarity is preferred for welding with the manual tungsteninert gas shielded process, but stabilized alternating current may be used.

All welds shall be built up by the application of multiple passes. The thickness of metalapplied for each pass shall not exceed 5 mm. Slag or flux shall be removed after eachpass, and the completed weld shall be cleaned of slag and spatter metal on all surfaces.

Preheat, post weld heat treatment, and non-destructive examinations shall be inaccordance with the applicable ASME Design Code (B31.1 or B31.3) as noted on eachPiping Material Classes in General Specification GD-07.

9 FIELD WELDING ALLOY PIPE

Section 8.0 shall apply except where superseded by the following items:

Materials shall be new, of first grade quality and of the type and grade specified.Mill test reports shall be obtained for all pressure parts and for parts welded topressure parts. There shall be no substitution of materials without prior writtenapproval from the Buyer.

The Vendor shall have an alloy identification system to maintain mill heat identityfor every plate, sheet, pipe, tube, bar, etc. or portion thereof. The markingsystem shall not damage the alloy mechanically, contain compounds that couldcause defects during welding, or contribute to corrosion of the alloy. Prior to theonset of fabrication and/or production welding, this procedure shall be submittedto Buyer for approval.

Due to adverse effects of embedded free iron in the surface of the Alloy 2205materials, several handling precautions must be observed.

Do not use iron or steel tools and handling fixtures. Only stainlesssteel wire brushes or abrasive disks and wheels and other grinding,fi i hi l i i t hi h h t b d i


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cleaned to eliminate all free iron contaminants. It is acceptable touse bending, shaping and forming equipment and dies ordinarily usedfor austenitic stainless steel or nickel base alloys; however, Alloy2205s much higher hardness and strength must be accounted for.

Piping fabrication under this specification shall be fusion welded, as set forthherein.

The first (root pass) shall be made by the tungsten inert gas process (TIG) ormetal inert gas process (MIG). TIG with 99.999% pure Argon gas shielding shallbe used for Titanium welding.

Alloy filler electrodes used with the automatic submerged arc process and theflux or melt used shall deposit weld metal of chemical composition and physical

properties similar to the base metal. Alloyed fluxes or melts in combination withmild steel or alloy wires shall not be used. Filler metal shall be ERTi-1 forTitanium welding. Filler metal for Duplex 2205 SS shall conform to AWS E2209.Bare wire or flux cored wire will be used. If Duplex 2205 is welded to a loweralloy such as SS 316, filler metal will correspond to specification AWS 309MoL.

All welds shall be built up by the application of multiple passes. The thicknessof metal applied for each pass shall not exceed 5 mm. The slag or flux shall be

removed after each pass, and the completed weld shall be cleaned of slag andspatter metal on all surfaces. Brushes, chisels, and other tools used forcleaning shall be of stainless steel material.

In Titanium welding, the minimum preheat temperature is 15C and maximuminterpass temperature is 93C. In Duplex 2205 welding, a minimumrecommended preheat is 21C and maximum interpass temperature is 249C.The weld will be allowed to cool below 149C before starting the next pass.

10 UNDERGROUND PIPING

10.1 General Requirements

The entire length of underground piping shall be supported by the bottom of the


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Bare tracing wire/lines shall be placed 152 mm above the top of theburied pipe with locating stations at:

(a) No more than 152 m intervals;(b) Both ends of any underground piping run;

(c) Junctions and turns.

10.2 Trenching Bedding and Back-Filling (All Piping)

Pipe trenches shall be excavated to the lines and grades shown on drawings.

The maximum width of the trench at approximately the top of the pipe(s) shallnot exceed the outside width of the pipe(s) plus 406 mm and the bottom shall be

prepared to provide uniform bearing throughout the entire pipe length.Where rock is encountered, it shall be removed to a depth of 150 mm minimumbelow bottom of pipe and back-filled with granular material for level or slightslopes, or sand mixed with clay for steep slopes and compacted to form thebottom of the trench. Backfill, sand bedding, and compaction shall be inaccordance with General Specification 000-GC-S-001.

Unsuitable material in trenches - such as expansive soils, organic, or loosematerial - shall be removed from the underside of pipe(s) and for a width of notless than one-diameter of the outermost pipe on each side of the pipeway. Thespace shall be back-filled with suitable material, as described below.

Piping shall be placed on a minimum base of 150 mm of granular beddingmaterial of minus 9.5 mm size. After installation and testing, additional beddingmaterial shall be placed around and over the pipe until a minimum of 6 inchesover the top of the pipe has been placed and compacted. Water shall be added

to this material to aid in compaction. The remainder of the trench shall be back-filled and compacted. Backfill material and compaction shall be in accordancewith General Specification 000-GC-S-001.

Walking or standing on top of pipeline shall be minimized until 305 mm of coverhas been placed.


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Oxygen concentrations below 19.5% by volume reduce the capacity to sustainlife and may cause asphyxiation. Extreme care must be taken to preventexposure to oxygen deficient atmospheres.When using any cleaning agent, adequate ventilation shall be provided.

All piping shall be pre-cleaned prior to installation to meet the cleanliness levelspecified in Section 11.4. Cleaning methods may include one or a combinationof the following:

a) Mechanical cleaning, such as, sandblasting, brushing, blowing, orotherwise physically removing contaminants.

Slagblasting

Only dry, oil-free air shall be used for blasting. Blasting material shall beglass or slag blast media and shall be clean and free of hydrocarboncontamination. Coal slag material, Black Beauty is prohibited for use asa blasting agent for oxygen service cleaning.

Slagblasting to gray metal is the preferred method for cleaning carbonsteel items whenever practical. Except for thoroughly removing particlesby blowing out, wiping, or vacuum cleaning, no further cleaning isrequired. The term slagblasting includes bead and slag blasting.Detailed information and requirements for slagblasting are given inGeneral Specification GC-12, Painting and Protective Coatings.

BrushingNote: Brushes with carbon steel bristles are only permitted to be used oncarbon steel. Stainless brushes are preferred. Copper, brass, or bronzebrushes may be used.

BlowingAfter any mechanical cleaning, the components or systems must becleaned by blowing, swabbing, or vacuuming.

Hand WipingHand wiping is a mechanical cleaning method using a clean, lint free


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SwabbingSwabbing is a mechanical cleaning method using a clean, lint free mop toclean areas on components or systems which are too large to clean byhand wiping. Readily accessible surfaces may be cleaned using only anEdgeless Mop, Part No. ELMOP (available from Contec Corp.) which is

moistened with a cleaning solution. Polyethylene pales or buckets areacceptable for use with the aqueous cleaners. Any pail or bucket usedfor swabbing must first be cleaned with the cleaning agent to be used.The material of construction of pails and buckets must be compatible withthe cleaning agent to be used.

b) Chemical cleaning, including the use of solvent or alkaline solution forgrease removal, acid-pickling (de-scaling), passivating, de-rusting, bright-

dipping, solvent or hot detergent flushing, immersion, spraying and/orwiping.

Note: If detergent is used, thorough rinsing with clean water andsubsequent drying with oil free dry-air or Nitrogen are required. If solventis used, the item cleaned must be thoroughly purged with oil-free dry airor Nitrogen.

Wherever possible all piping shall be of welded construction, except at

connections to valves, meters, etc., where threaded or flanged joints arerequired.

Welding procedures, welder's qualification test, welding operations and testing ofwelds shall be in accordance with ANSI B31.3.

Backup rings and internal alignment clamps shall not be used. The first or rootpass of welding shall be made by tungsten inert gas (TIG) process.

Workers shall keep their hands washed and clean of oil, dirt, grease, etc. andwear reasonably clean, non-oily work clothes.

Tools, such as wrenches, etc., that are designated for use on the oxygen pipingsystem shall be kept clean and set aside for this purpose only.


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11.4 Required Cleanliness Level

Accessible significant surfaces must be free of contaminants visible to the nakedeye when viewed under bright light. A final check of absence of oil and greaseshould be performed with the use of an Ultraviolet (UV) light source. Inaccessible

significant surface must pass indirect inspection by examination of wipings,swabbing or flush liquids, as described in Section 11.5.

The following contaminants shall not be allowed to remain:

a) Hydrocarbon oils and greases

b) Unapproved pipe-threads or gasket sealant

c) Water

d) Conventional paints, varnishes, fluxes, or organic rust

e) Loose or loosely adherent rust or mill scale, shop dirt, filings, chips, orloose weld spatter.

The following are not considered objectionable contaminants and may be

allowed to remain:

a) Tightly adherent (not removable without grinding) mill scale or weldspatter.

b) Light rust film. See paragraph 11.5 (a) Note 1.

11.5 Cleanliness Inspection Methods

Items cleaned for oxygen service should be inspected by the method givenbelow which applies to the particular item. Parts, which will be inaccessible toinspection after assembly, must be inspected prior to assembly. If inspectionreveals the presence of any contaminants, the item must be re-cleaned. Usuallywiping the contaminated area with a clean cloth moistened with an approved

l t ill d t l l th P i t t j ti i


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Note 1: A light film of rust is acceptable. The Steel Structures PaintingCouncil Pictorial Standard B Sa 2 (ASTM D-2200-67) showsan acceptable condition.

Ultraviolet (Black Light) Inspection: In addition to direct visual inspection,this method shall be used to detect common oils and greases. Examine

the surface in darkness or subdued light using a 3200-3800 AUwavelength ultra-violet (black) light. If a bluish-white fluorescent blotch,smear, smudge, or film is present, re-clean the item. Typical acceptablemodels of ultra-violet lamps are SPECTROLINE Models B-100 and SL-3660 manufactured by Black Light Eastern Division of Spectronics Corp.Westbury, Long Island, New York.

Note 2: Fluorescent specks due to lint and mildly fluorescent stains

from detergent residues are acceptable, except in excess.b) Wipe Test: This method should be used to check the cleanliness of

inaccessible surfaces or for verifying the cleanliness of an item with alarge surface area. Wipe the item or at least one square foot of itssurface, whichever is smaller, with clean white paper or unbleached cloth.Examine the cloth or paper under both bright and ultra-violet (black) light.If excessive discoloration or any bluish-white fluorescence appears, thesurface requires re-cleaning. Suggest cloth manufacturer is Contec

Corp. Item No. PNHS 1212, available from Contec Corp., P.O. Box 530,Spartanburg, SC 29304, Telephone No. (800) 289-5762.

Note 3: A slight discoloration resulting from a light film of oxide isacceptable (see also Note 1).

c) Solvent-Color Test: This method should be used to check the cleanlinessof inaccessible surfaces, which have been flushed with a solvent.Thoroughly flush the item with solvent and collect a sample of the

draining in a clear glass jar. Compare a pint jar filled with used solventwith a pint jar of unused solvent by holding both up to the light andviewing them simultaneously through the side. There should be fewsuspended particles and little, if any, difference in color between the two.If contamination is present, the item should be re-flushed with the solvent.

d) Odor Test


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Take three (3) deep breaths.

Then, with your lungs full, place your clean, ungloved and cupped hand inthe gas stream. Bring your cupped hand to your nose and sniff yourhand. If no odor is detected, then fan the venting gas toward your nose.

For components and systems not being purged, fan the air at the openingof the component or system to your nose using your clean, ungloved andcupped hand. Sniff your hand; if no odor is detected, then directly sniffthe opening of the component or system being tested. An acceptabletest shall e one in which no odor is detected.

If at any time during this test an odor is detected, the system orcomponent shall either continue to be purged for a period of not less than

thirty (30) minutes or until no odor can be detected. If the odor persists,then the system shall be re-cleaned.

11.6 Use of Citrikleen HD Cleaning Solution

Table A Citrikleen HD Aqueous Solutions

Specification Contamination Concentration(Product : Water)

Temperature

Immersion30 minutes2 4 hoursOvernight

Grease & CarbonLightModerateHeavy

1:4 1:201:2 1:101:1 1:2

Ambient to 43oC

Immersion1 4 hours

Solidified Greases 1:1 1:2 Ambient to 43oC

Immersion30 90 minutes

Gelled Oils 1:1 1:5 Ambient to 43oC

Immersion4 hours overnight Specialty Lubes 1:1 1:2 Ambient to 43o

C

Note: Agitation and heating solution to 43oC will accelerate cleaning.

WARNING: DO NOT HEAT ANY CONCENTRATION OF A CITRIKLEEN HD


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Note: Rinsing effectiveness is improved if warm (approximately 49oC F) cleanwater is used.

Citrikleen HD residue DOES fluoresce under ultraviolet light. If any cleanedcomponent or system fluoresces, the oxygen service component or system shallbe rinsed with clean water again to remove any cleaning agent residue. Should

the fluorescence persist, then re-clean the oxygen service component or system.

Refer to Manufacturers MSDS and other furnished data for materialcompatibility.

11.7 Drying and Purging

All components and systems that require rinsing with clean water must be

immediately drained of all residual water and then immediately dried to avoid theformation of surface rust. Drying may be accomplished using dry, oil-free air ornitrogen, applying heat directly to the components and systems, blowing with afan or exposing components and systems to direct sunlight.

If components or systems cannot be positioned such that all rinse water readilydrains from it, then forced air drying techniques such as using heated oil-free airor heated nitrogen must be used to ensure that all water is removed from thecomponents or system.

Note: The appropriate drying method must be based on the materials ofconstruction of the component or system and the configuration of thecomponent or system.

Interior surfaces of components or systems cleaned with solvent must be blowndry using dry, oil-free air or nitrogen, applying heat directly to the components orsystems, blowing with a fan, or exposing components or systems to direct

sunlight. All traces of cleaning solvent odor must be removed from thecomponent or system by the drying process used.

11.8 Documentation Requirements

All cleaning and inspection of components or systems used in oxygen servicet b it bl d t d Th tt h d f h ll b d d fill d i


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Serial Number (for valves and equipment)

b) Section II, Oxygen Service Cleaning Data

This section is required when performing any oxygen service cleaning.

Location of cleaning (Job Site or at manufacturer); Date of cleaning; Method of cleaning (Mechanical, Flushing, Immersion, Vapor

Degreasing, Blasting, etc.); Cleaning agent used (e.g., Blue Gold); Agent strength (e.g. 1:20 dilution of Blue Gold Industrial Cleaner

with water); Agent quality after cleaning (pH, color, etc.);

Rinse.

c) Section III, Equipment Inspection Data

This section is required of all equipment Cleaned for Oxygen Service,which includes items purchased as such.

Inspection date;

Location of inspection (Job Site); Part Labeled (Yes or No); Part protection (Capped, Bagged or both); Method(s) of inspection (White light, UV light, Wipe Test, Odor

Test, etc.); Inspection Result (Pass, Fail). If a component fails an inspection,

it shall not be installed until it is re-cleaned and passes theinspection (this must be documented in the next column).

Inspectors printed name and signature; The printed name and signature of person reviewing the

documentation.

All documentation produced for a job must be kept with the equipment file(s) forthat job.


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12 GENERAL PROCEDURES FOR PRESSURE TESTING

12.1 Preparation

The following procedure outlines the method to be used in testing all process,service and utility pipe installations. All piping systems shall be tested in

accordance with these requirements. See Section 11.0 for oxygen piping.

A complete pressure test shall be performed on all lines and equipment uponcompletion of construction work but before insulation at joints is applied.

Prior to filling a system for testing, all pipelines shall be cleaned thoroughly. SeeSection 14.0.

Care shall be exercised in testing so the applied pressure is limited to thatportion of the system being tested. Isolate other systems where required.

Pressure gauges and pressure parts of instruments together with pipingconnecting to main pipelines or equipment may be tested at the same testpressures as the main piping or equipment provided that the test pressure doesnot exceed 80% of the instrument scale range. If test pressure is more than80% of scale range, the instruments shall be removed and their connectionsplugged. Reinstall after test.

Pressure relief and thermal expansion relief valves shall be excluded from thepressure tests. Blinds shall be installed adjacent to their inlet and/or outletflanges during tests. Screwed relief valves shall be removed and theconnections plugged during the test.

Lines containing check valves shall have the source of pressure locatedupstream from the check valve so the pressure is applied under the seat. If this

is not possible, the check valves shall be removed, blanked off, or the discspropped open.

Control valves shall be set in the wide-open position.

Orifice plates, which interfere with filling, venting and draining, shall be removedi t t ti Wh i j i t d i i i th h ll t b


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tested independent of piping systems shall be excluded from the line pressuretest. However, simultaneous test of exchangers and/or vessels with connectedpiping may be performed provided that the test pressure used is not higher thanthat permitted for the equipment.

12.2 Hydrotesting

Lines shall be purged of air before the hydrostatic test pressure is applied.Vents shall be open when draining the systems.

Potable water shall be used for hydrotesting high-pressure oxygen. See Section11.0 for desired cleanliness for oxygen service.Water for hydro testing stainless steel piping shall not contain more than 50-PPMchloride.

Care shall be exercised in order to prevent temporary concentration of excessiveloads on the support structure. Provide temporary supports where necessary.

The test pressure on any section of the line shall be limited to the test pressurespermitted on any exchanger, separator, strainer, expansion joint, or otherappurtenance and equipment installed in the line.

Hydrostatic test pressures shall be maintained for a sufficient length of time (30

minutes minimum) to permit close visual or hand-wiping inspection of all joints.

No lines shall be hydrostatically tested to less than 345 kPag except sanitarylines and drains. Sewer and drain lines shall be tested at a minimum hydrostatichead of 3 m.

Re-testing of lines, after repair, shall be done at the pressure originally specifiedfor the test.

After completion of hydrostatic testing, temporary blanks and blinds shall beremoved and lines shall be completely drained. Valves, orifice plates, expansion

joints, etc. shall be reinstalled. After the lines have been drained, temporarysupports shall be removed.

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15 CHEMICAL CLEANING AND PICKLING

Vendor shall submit MSDS (Material Safety Data Sheets) for all chemicals used incleaning the pipelines. The use and disposal of chemicals used in the cleaning shall becoordinated with the Owner for disposition or licensing requirement.

Titanium piping shall be cleaned in accordance with ASTM B600.

Piping shall be chemically cleaned after being assembled into a circulation system toassure complete circulation and elimination of dead ends or branches, which can causegas traps.

Where chemical cleaning and/or pickling of piping is required for the removal of rust, millscale, mill varnish, dirt, grease, or other contaminants, the following procedures shallapply.

Prior to chemical cleaning, carbon steel pipe spools shall be mechanically cleaned asspecified in Section 14.0. For oxygen piping, see Section 11.0.

Piping to be cleaned shall be disconnected or blanked off from mechanical equipment.Chemicals shall not be circulated through bearings, cylinders, oil filter cartridges, oilreservoirs, instruments, valves (except where valve materials are resistant to thechemical solutions used), etc.

All screens, filters and orifice plates shall be removed prior to chemical cleaning.

The flow rate shall be 0.5 m/s per inch of nominal pipe size or 1.83 m/s whichever isless, minimum through the piping.

All solutions, during the re-circulation sequences shall be filtered through the utilizationof 40-micron Full-Flo filters or equivalent with Dynel Elements to assure removal of all

residual contamination.The following stipulations are to be interpreted as minimum requirements for cleaningcarbon steel. This procedure shall include, but not necessarily be limited to theserequirements alone to achieve the desired intent of this procedure. All referencedchemicals shall be considered on an "or equal" basis. Exceptions to this specification

b d ith itt l b th B


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15.3 Pickling

For pickling of carbon steel piping, especially where system valves are includedin the operation, it is desirable to utilize an inhibited phosphoric acid materialreadily available through the chemical compounding distributors (i.e. Turco,Oakite, CeeBee, etc.).

Do not use hydrochloric acid for any pickling.

During pickling, circulate the selected solution at the manufacturersrecommended concentration, temperatures, and time duration or until thedesired pickle is achieved as evidenced by visual observation.

The duration of the application shall be of sufficient length to give greater than 5micron etch on the most vulnerable alloy in the composite metallurgical system.

15.4 Rinse

Rinse the pickled system with filtered fresh water until an effluent pH of 6 to 8 isachieved on all parts of the system as indicated by Hydrion paper or equal.

15.5 Passivate

To passivate the piping, drain the rinse water from the system and passivate thesystem with a mixture of 0.25% by weight Disodium Phosphate and 0.50% byweight Sodium Nitrite.

Circulate the mixture at 82C for 30 minutes and flash-dry by removing from thesystem while hot with dry, hot, filtered, (30 micron) air or nitrogen.

Immediately following the flash-drying, flush the system with water-displacing,

non-detergent mineral oil and rust preventative solution.15.6 Valves

Ferrous valves shall be cleaned by submerging them in a warm (43C to 49C)alkaline solution 1/4 percent trisodium phosphate (TSP) for fifteen to twenty

i


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protect against the possible entry of foreign matter, moisture, etc. until the entiresystem is ready for operation. Flanged ends shall be sealed using tape andpolyethylene sheeting. Threaded or socket weld connections and butt weld endsshall be tightly sealed with polyethylene or plastic plugs (or cans) secured withtape. Tape used for securing covers shall be of a vinyl waterproof type.

16 PIPE SUPPORTS

Pipe supports shall be in accordance with the drawings 000-DW-P-101 through 000-DW-P-122.

Welds, when not specified, shall be 6.35 mm fillet.

Uninsulated piping shall be supported as shown on drawings 000-DW-P-101 through000-DW-P-122, unless shown otherwise.

Insulated piping 50 mm NPD and larger shall rest on pipe shoes, saddles, or otheradequate means of protecting insulation. Shoes for carbon steel pipe shall be welded tothe piping. Shoes for alloy pipe, galvanized pipe, and plastic pipe shall be welded tocarbon steel clamp attached to the pipe.

Pipe support clips or attachments to vessels, steel columns, or beams by welding shall

be installed by metal arc welding (MAW) process. No oxyacetylene gas welding shall beused.

Galvanized surfaces, which have been field welded, shall be repaired by the applicationof "GALVICON" manufactured by the GALVICON Corporation of New York, or ApprovedEqual.

Where shims are called for on steel supports, the shims shall be tack welded to the

supporting steel.All anchors, stops, guides, and spring supports are to be installed only where indicatedon the piping drawings.

All structural steel members shown are specified as ASTM A36 standard. If non-ASTMt d d b b tit t d i l t b d ith l b th


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imposed upon them by the expansion of pipe, weight of pipe and contents, windpressure etc. Lines shall not be extended by means of a dead-end branch for thepurpose of providing support without written approval of the Buyer.

Piping may rest upon or be suspended from its supporting structure.

Piping and support systems shall be designed so that the expansion forces and slidingfriction transmitted to structural members of the building are minimized. Pipe anchoringmay be done by welding the web of a structural tee section to a reinforced section of thepipe and the flanges of the "T" to the supporting structure or other method approved bythe Buyer.

Insulated pipes shall have insulation protected by means of shoes or saddles onhorizontal runs as detailed on the drawings.

For maximum recommended spacing between pipe supports, see General Specification000-GD-P-006, Piping Design.

17 PAINTING

In plant carbon steel pipes only shall be painted and identified in accordance with Table1A.

Overland pipes, Stainless Steel, HDPE and Plastic pipes do not require painting, butrequires identities accordance with table 1A.

All identification shall de in Spanish.

18 LIST OF ATTACHMENTS

Pressure Test Record FormTable 1A - Legend of Labels and Color CodingTable 2 - Size of Legend LettersOxygen Service Cleaning and Inspection Checklist

3

3


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PRESSURE TEST RECORD

Facility Name: (PLV, Conc. Leaching, etc.) System Name: (Identify operating fluid.)

Type of Test: (Specify sequence if applicable) Pipeline Tested: (Identify by Line Numbers.)Pneumatic: 1.

Static: (Specify liquid type.) 2.

In Service:

Hydrostatic: (Specify Fluid Type) 3.

Drawings: (List Isometric drawings where pipelines are shown.)1. 5.2. 6.3. 7.

4. 8.Pipeline Design Operating Pressure (kPag): Pipeline Design Operating Temperature (C):

Pneumatic / In Service Test Static / Hydrostatic TestStarting Starting

Time: Time:

Pressure: Pressure:Temperature: Temperature:

Finish Finish

Time: Time:

Pressure: Pressure:


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TABLE 1A: LABELS AND COLOR CODING LEGEND

PipeNatl

CODIGODE

SERVICIODESCRIPCION LEGENDS FOR LABELS COLOR DETUBERIA

CUBIERTADE CAMPO LETRAS

SERVICECODE

DESCRIPTIONPIPE PAINT

COLOURFIELD COVER

COLORLETTERING

COLOR

Spanish Spanish Spanish Spanish

English English English English

WATER, ABOVE GROUND AGUA, SOBRE TIERRA

SUMINISTRO DE AGUA DEENFRIAMIENTO VERDE VERDE BLANCOCS CWS COOLING WATERSUPPLY

COOLING WATER SUPPLY GREEN GREEN WHITERECUPERACION DE AGUA DEENFRIAMENTO

VERDE VERDE BLANCOCS CWR COOLING WATERRETURN

COOLING WATER RETURN GREEN GREEN WHITE

AGUA PARA USO D0MESTICO VERDE VERDE BLANCOCS DW DOMESTIC WATER

DOMESTIC WATER GREEN GREEN WHITE

AGUA DE INCENDIO ROJO ROJO BLANCOCS FPW FIRE PROTECTIONWATER FIRE PROTECTION WATER RED RED WHITE

AGUA FRESCA VERDE VERDE BLANCOCS FRW FRESH WATERFRESH WATER GREEN GREEN WHITE

AGUA DE SELLO GREEN GREEN WHITECS GSW GLAND SEAL WATER

GLAND SEAL WATER VERDE VERDE BLANCO

AGUA DE PROCESO GREEN GREEN WHITECS PRW MILL WATER

MILL WATER VERDE VERDE BLANCO

AGUA POTABLE GREEN GREEN WHITECS PW POTABLE WATER

POTABLE WATER VERDE VERDE BLANCOAGUA CRUDA VERDE VERDE BLANCO

CS RW RAW WATERRAW WATER GREEN GREEN WHITE

AGUA DE OSMOSIS REVERSA VERDE VERDE BLANCOCS RO REVERSE OSMOSIS

REVERSE OSMOSIS GREEN GREEN WHITE

3


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PipeNatl

CODIGODE

SERVICIODESCRIPCION LEGENDS FOR LABELS COLOR DE

TUBERIACUBIERTADE CAMPO

LETRAS

SERVICECODE DESCRIPTION

PIPE PAINTCOLOUR

FIELD COVERCOLOR

LETTERINGCOLOR

OIL & GAS, HYDROCARBONS

ACEITE COMBUSTIBLE GRIS GRIS NEGROCS FO FUEL OIL

FUEL OIL GREY GREY BLACK

GASOLINA GRIS GRIS NEGROCS GAS GASOLINE

GASOLINE GREY GREY BLACK

GRASA GRIS GRIS NEGRO

CS GR GREASE GREASE GREY GREY BLACKACEITE HIDRAULICO, HP GRIS NEGRO

SS HOH HYDRAULIC OIL, HPHYDRAULIC OIL, HP

NOGREY BLACK

ACEITE HIDRAULICO, LP GRIS NEGROSS HOL HYDRAULIC OIL, LP

HYDRAULIC OIL, LPNO

GREY BLACK

ACEITE DE LUBRICACIN, HP GRIS NEGROSS LOH LUBE OIL, HP

LUBE OIL, HPNO

GREY BLACK

ACEITE DE LUBRICACIN, LP GRIS NEGROSS LOL LUBE OIL, LPLUBE OIL, LP

NOGREY BLACK

GAS NATURAL GRIS GRIS NEGROCS NG NATURAL GAS

NATURAL GAS GREY GREY BLACK

GAS PROPANO GRIS GRIS NEGROCS PG PROPANE GAS

PROPANE GAS GREY GREY BLACK

CARGA ORGANICO NO GRIS NEGROSS LO LOADED ORGANIC

LOADED ORGANIC NO GREY BLACKESTERILES ORGANICOS NO GRIS NEGRO

SS BO BARREN ORGANICBARREN ORGANIC NO GREY BLACK

REAGENTS

ALUM AMARILLO NEGROHDPE AL ALUM NO

3


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PipeNatl

CODIGODE

SERVICIODESCRIPCION LEGENDS FOR LABELS COLOR DE

TUBERIACUBIERTADE CAMPO

LETRAS

SERVICECODE DESCRIPTION

PIPE PAINTCOLOUR

FIELD COVERCOLOR

LETTERINGCOLOR

LECHADA DE CAL AMARILLO NEGROHDPE ML MILK OF LIME

MILK OF LIMENO

YELLOW NEGRO

HIDROSULFURO DE SODIO AMARILLO NEGROHDPE NA SOLDIUM

HYDROSULFIDE SOLDIUM HYDROSULFIDENO

YELLOW NEGRO

HIDROSULFURO DE SODIO GRIS AMARILLO NEGROCS NA SOLDIUM

HYDROSULFIDE SOLDIUM HYDROSULFIDE GREY YELLOW NEGRO

XANTATO AMILICO DEPOTASIO AMARILLO NEGROHDPE PAX POTASSIUM AMYXANTHATEPOTASSIUM AMY XANTHATE

NOYELLOW NEGRO

AEROFLOAT 238 AMARILLO NEGROHDPE RAF AREOFLOAT 238

AREOFLOAT 238NO

YELLOW NEGRO

SILICATO DE SODIO AMARILLO NEGROHDPE RSS SODIUM SILICATE

SODIUM SILICATENO

YELLOW NEGRO

ACIDO SULFURICO AMARILLO NEGROSS SAC SULFURIC ACID SULFURIC ACID NO YELLOW NEGRO

SODA CAUSTICA AMARILLO AMARILLO NEGROCS SH CAUSTIC SODA

CAUSTIC SODA YELLOW YELLOW NEGRO

AMONIACO ANHIDRIDO AMARILLO NEGROSS AHA ANHYDROUS

AMMONIA ANHYDROUS AMMONIANO

YELLOW NEGRO

ACUOSA DE AMONIACO AMARILLO NEGROSS AQA AQUEOUS AMMONIA

AQUEOUS AMMONIANO

YELLOW NEGRO

COMPRESSED AIR SYSTEMS

AIRE DE SOPLADOR AZUL AZUL BLANCOCS BA BLOWER AIR

BLOWER AIR BLUE BLUE WHITE

AIRE DE INSTRUMENTACION AZUL AZUL BLANCO

3


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Table 1 Notes:

1. For all insulating tubes and pipes unpainted, such as stainless steel andplastic pipes, colored labels are used for identification of the contents of thepipe. "Color field" refers to the color of the basis of these labels. The colorsshall be as recommended in the standard NPT 399 012 (Color identification

of pipes for the transport of fluids in gaseous or liquid at ground facilities andships).

2. Indicate operating pressure and temperature for steam lines.

3. The size of the letters on the labels shall be per Table 2.

4. All internally-lined carbon steel piping shall bear the wording NO ESTA PERMITIDO

SOLDAR ESTA TUBERIA next to the Label, in Spanish.5. Take special note that all rubber-lined pipes must be identified as REVESTIDA DE

GOMA, in Spanish.


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TABLE 2 - SIZE OF LEGEND LETTERSOutside Diameter

of Pipe or Covering, Note 2mm

Minimum Length ofColor Field, Note 1

mmSize of Letters

mm

20 to 32

( to 1 )

200

(8)

13

()38 to 50

1 to 2)

200

(8)

20

()

65 to 150

(2 to 6)

300

(12)

32

(1 )

200 to 250

(8 to 10)

600

(24)

65

(2 )Over 250

(Over 12)

820

(32)

90

(3 )

Table 2 Notes:

1. Minimum length of color field applies to colored labels used in insulated and

unpainted pipes.2. For identification of materials in pipes of less than 20 mm NPD, a tag made of

stainless steel sheet with the label embossed shall be permanently attached to thepipe.


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Page 34 of 34

OXYGEN SERVICE CLEANING & INSPECTION CHECKLIST

I. REQUIRED INFORMATION

Quantity

Component

Manufacturer

Model or Line Number

Serial Number

II. OXYGEN SERVICE CLEANING DATA

Cleaning LocationDate of Cleaning

Cleaning Method(s) Flushing Blasting

Mechanical Wiping

Immersion Spray

Washing

Vapor Degreasing

Flushing Blasting

Mechanical Wiping

Immersion Spray

Washing

Vapor Degreasing

Flushing Blasting

Mechanical Wiping

Immersion Spray

Washing

Vapor Degreasing

Flushing Blasting

Mechanical Wiping

Immersion Spray

Washing

Vapor Degreasing

Cleaning Agent(s)

Agent Strength

(Dilution Ratio)

Rinse Yes N/A No Yes N/A No Yes N/A No Yes N/A No

III. EQUIPMENT INSPECTION DATA

Inspection Date

Location of Inspection

Part Labeled Yes N/A No Yes N/A No Yes N/A No Yes N/A No

Protection UsedMethod(s)

Inspection

White Light UV Light

Odor Test Wipe

Test


Odor Test Wipe Test


Odor Test Wipe

Test


Odor Test Wipe Test

Inspection Result Pass Fail Pass Fail Pass Fail Pass Fail

Inspector Printed Name: Signature:

000-gc-p-009 r.3 piping installation.pdf

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