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Tia Maria Project

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Tia Mara Project









B 10/12/07 EB JVR Issued for bidding

DISTRIBUTION A B C 0 1 2 3 4 5 6 7 8 9 10

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1.0 GENERAL 03

2.0 REFERENCES : Standards and Codes. 03


























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1.1 Scope

This specification covers the general requirements for the installation of Steel,
PVC and HDPE piping systems for the Tia Maria Project for Southern Peru.

1.2 Work included
Minor materials requirements.
Cleaning and flushing
Services identification
Inspection and testing ( QC ).
Painting and identification

1.3 Work excluded
Material purchase
Unloading and storage

1.4 Requirements

The process and service pipelines must be prepared and installed according to
the reference standards, the drawings of the project, the class and the materials
of the pipes according to the design and requirements established in this

All installations must be executed following good industrial practices, in
compliance with procedures verified by the Quality Control of the installer,
conveniently recorded and filed.

In the event of a conflict between the aforementioned documents, this
Specification shall prevail, except where another legal provision is otherwise


2.1 Standards

Unless otherwise specifically indicated, all the work must be carried out
according to the requirements of the latest reviews of the applicable codes and
regulations, which must include but not be limited to the following:

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ANSI American National Standards Institute
API American Petroleum Institute Standards
ASME American Society of Mechanical Engineers
ASNT American Society for Non-Destructive Testing
ASTM American Society for Testing and Materials
AWWA American Water Works Association
AWS American Welding Society
FM Factory Mutual Engineering Division Recommended Practices
HI Hydraulic Institute
MSHA Mine Safety and Health Administration
MSS Manufacturers Standardization Society of the Valve and Fittings
NFPA National Fire Protection Association
OSHA Occupational Safety & Health Administration
UL Underwriters Laboratories Inc.

2.2 Codes

When the regulations, laws and statutes of the local codes have priority over the
ASTM or ANSI standards, such regulations, laws, statutes or codes must prevail
and this fact shall be indicated in the project drawings.

Materials, installation, tests and inspection should be in agreement with the last
edition of the following codes

ANSI B31.3 Code for Chemical Plant and Petroleum Refinery Piping.
AWWA C200 Code for Steel Water Pipe.

Whenever other codes apply such as the fire, refrigeration or health protection
codes, these shall be indicated in the drawings of the Project.

The installation, tests and inspection of the reinforced plastic fiberglass (FRP),
the high density polyethylene (HDPE) and polyvinyl chloride (PVC) and other
thermoplastic pipe materials must be manufactured according to ANSI B31.3.

2.3 In addition to the standards and their referential specifications, the following
specifications must be considered in its last revisions..

25329-220-3DR-G01L-0001 General Site Conditions
SPCC-PTM-P-DC-001 Piping Design Criteria
Line List.
SPCC-PTM-C-TS-006 Painting Specification
SPCC-PTM-P-TS-003 G. S. for fusion welding at field & Shops
Of HDPE pipelines.
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DETAIL DRAWINS with latest revision and approved for construction.


3.1 Materials

Piping materials shall be in accordance with Piping Material Specification for
this Project.
Substitutions, including thicker wall materials, are not permitted without written
authorization of Southern Peru authorized representative.
Installer contractor shall visually inspect every pipe and component and reject
items that contain injurious defects are internal or external surface gouges, scars,
scratches, blisters, or discontinuities that produce a notch effect or reduce the
specified wall thickness by 5 percent or more.
PVC piping should be handled, stored, cut, welded and tested in strict
accordance with manufacturers instructions, which will take priority over this
specification in the event of conflict.
Store material provided by Southern Peru , or purchased for this project, in an
area where exposure to heat, dirt, and contamination is avoided.
PVC piping must be stored on flat surface without coming into contact with
point loads, piping shall be arranged a layers. Pipe more than 20 in diameter
shall only be piled in two layers and shall be secured to prevent movement. The
maximum pile height is two meters.

3.2 Piping

Contractor shall shape or bevel the joints to be field welded .
Adjacent sections of longitudinal welded pipe that are joined by butt welding
shall have the longitudinal weld seams positioned so that they are at least 30
degrees apart above the horizontal centerline.
Temporary support shall be installed, as necessary for pipes, valves, specialty,
For the PVC piping lines the installer contract is responsible for the quality of
the bonding. Shall prepare bonding procedure specifications and conduct the
required performance qualification test to qualify bonding procedures and
bonders or bonding operators. Will be according ASME B31.3 .

3.3 NDE (Non Destructive Examination) for steel piping lines

The extend of nondestructive examination shall be in accordance with chapter
VI of ASME B 31.3 Nondestructive examination methods, acceptance criteria,
and additional general requirements shall be as follows, unless otherwise
authorized in writing by Southern Peru.

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Service Lines ( Up to and including 150#) 5 % spot RT ( CD as necessary )
Process Lines 10% spot RT (CD as necessary)
Highly toxic, highly flammable or highly 20% spot RT (CD as necessary)
explosive lines.

RT : Radiographic testing
UT : Ultrasonic testing.
CD: Magnetic Particle and/or Dye Penetrant.


4.1 General

Coordinates, dimensions and elevations are indicated in the drawings.
All the installation drawings must be signed and approved for
CONSTRUCTION and the installer is responsible for keeping the latest version
at the site.
Prior to the mounting of the pipes, the installer must inspect the route indicated
in the drawings and confirm the feasibility of the installation. The pipes must be
installed as shown in the project drawings, however any interference or
discrepancy, regardless of its nature or origin, must be settled by the installer.
Any amendments required to solve such inconveniences must be made by the
installer and approved by the authorized representative of Southern Peru.

If the routing and layout of the pipes of less than 1 are not fully detailed or
shown in the projects drawings, these must be determined onsite following the
requirements of the P & ID and in accordance with the authorized representative
of Southern Peru.

The installer is responsible for the suitable storage at the project site of the pipes
waiting to be installed. The ends of the referred pipes must remain sealed until
the moment prior to their installation to prevent the contamination of their
internal walls.

PVC pipes can not drag across rocks or roads which could cause scratches and
gouges. Do not install underground piping when the soil is wet.
Do not backfill PVC pipelines with rocks or coarse fill. Provide a 300 mm cover
of clean fill over PVC piping prior to any coarse back fill material.

The actuator of valves may be rotated by the contractor only with prior
authorization from Southern Peru authorized representative.

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Pipe supports shall be in accordance with specification No SPCC-PTM-P-TS-
002 and drawings for installation.

When construction pipeline crossings of roads, maintain safety precautions such
as signs, lights and guards in the interest of public safety. A temporary bypass
must be provided.
Install culverts at road crossings as shown on the piping drawings . Allowable
loads shall be according to AASHTO standards.

4.2 Vents and Drains

Vents in high points and drainages in low points must be provided to facilitate
hydrostatic testing, cleaning, maintenance and operation of the system, as
outlined in the drawings and the P&ID of the Project.

The drainage points of the equipment and pipes located up to 1,5 meters from
the floor slab shall not require drainage pipes unless specifically shown in the
projects drawings. All drainage points above 1,5 meters must be equipped with
pipes to discharge the floor drains or in the catch basin. Valves for the vents and
drains must be installed according to the drawings developed by the Detailed

4.3 Inspection before mounting

All the pipe spools and loose pipes must be inspected before mounting to
make sure that they are damage free, with no dirt or any foreign substance. The
damaged items must be reported in writing to the authorized representative of
Southern Peru.

The prefabricated spools must be examined to verify that the identity of each
piece is correct according to the approved installation drawings.

4.4 Pipe expansion

The expansion joints must be anchored and installed according to the
manufacturers instructions to make sure that their free play is not damaged
during maximum expansions and contractions. The expansion joints must be
removed prior to the hydrostatic test.
The pipes must be installed to prevent interferences due to the expansion or
contraction of the adjacent pipes.

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4.5 Equipment and pump connections

All equipment and pump connections must be installed without exercising stress
on the line, taking into account all the contractions due to welding or
constructive misalignments. The cold spring coupling of the pipes or forcing
the interconnecting pipes to make them connect shall not be allowed.

If the nozzles or the alignment of the equipment and pumps are impaired due to
a faulty or deficient installation, the installer shall be responsible for all the
actions taken to solve the problem. In flanged connections, the pipes must be
installed and supported in such a manner so as to achieve an exact alignment of
the holes for the bolts and an even contact without exercising stress over the
total area of the packing. The pipes must not be supported from the flanges of
the equipment during construction. The pipe supports must be suitably located
to prevent overloading in the lines and equipment.

Under no circumstance must the ground connection be welded in the base plates
of the mechanical equipment nor shall the ground connection be made through
the equipment. The brazing tongs must be as close as possible to the point where
the welding is being performed.

4.6 Insulation for galvanic corrosion

Insulation flanges must be installed in the flanged connections between the
cathode protected surface pipes and the underground pipes. In the case of the
steel pipes on the surface coupled with cast iron underground pipes, the
transition must consist of a non-conductor pipe adaptor. Only when the cast iron
pipes have a molded elastic packing installed in the plant can it be directly
coupled to the steel pipe.

Special care must be taken upon installing the insulation kit to avoid damaging
the sleeves of the bolts, the packings and the washers. Having completed the
coupling it must be tested with the Megger, DVOM, or a similar device to
secure electrical isolation. The required reading must exceed 10.000 Ohms.

The ground connections of the weldings must not be installed using isolation

4.7 Pipe threaded connections

The threaded connections must be sealed with 13mm wide by 0.08mm/0.1mm
thick Teflon tape or a similar component, unless the connection is sealed by
welding. For temperatures above 260 C, use Armite N 250, lead plate,
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Molycote G or similar component, unless the connection is otherwise weld-

The machine oil to make the thread of the pipes or to cut must be eliminated
with solvent before applying the tape or the sealing component.

4.8 Seal welding for threaded connections

When the specifications of pipe materials stipulate that the threaded carbon steel
and stainless steel connections must be sealed by welding, the referred welding
shall be penetration groove welding. Special care must be taken to make sure
that a minimum of master wire (hilo macho) is left exposed in the adjustments.
Compounds for sealing thread or tape must not be used. No tape or thread must
be left exposed after soldering. Welding in malleable iron shall not be allowed.

4.9 Coupling of pipe with grooved ends

The Victaulic pipe must be installed according to the Victaulic connection
manufacturers assembly instructions.

Couplings Style Number 77 : the separation between the ends of the pipes and
the maximum admissible movement between pipe ends provides a relation
between the coupling and the rear end of the pipes groove. In order to achieve
an equal contraction and expansion, the visible space on either side of the
coupling must allow for of the maximum admissible movement at the end of
the pipe for a total separation of pipes of of the maximum admissible

Couplings Style Number 07 Zero-Flex : this coupling is rigid and does not allow
the pipe to accommodate to the expansion or contraction. The separation
between pipes cannot be adjusted onsite. Its installation shall be carried out
according to the instructions of the manufacturer.

Victaulic Flanges Style 741, 742, 742SF : These elements are designed to rest
against a regular and hard surface. A metal washer must be inserted between the
Vic-Flange and the accompanying flange for the following applications:

a) when the Vic-Flange is connected against an irregular flange (in other words,
cast steel gate, globe or check valves). The washer and a packing must be placed
between the referred washer and the irregular flange.

b) when the Vic-Flange is connected to a rubber cased flange, the washer must
be installed but in this case additional packing is not required.

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4.10 FRP, PVC, HDPE and casing pipes

The fiberglass reinforced pipes (FRP) must be handled, stored and installed
according to the installation instructions of the manufacturer. All the parts must
be eye-inspected for possible damages. The damaged parts must be cut or
repaired. The protection seals of the ends of the pipe must not be removed until
the moment of fabrication.

The polyvinyl chloride pipes (PVC) with cemented socket joints must be
installed according to the manufacturers instructions. The solvent cement must
not be used beyond its date of used recommended by the manufacturer.

The high density polyethylene pipes (HDPE) must be welded/soldered according
to the General Specification for Workshop and Onsite Fusion Welding N
SPCC-PTM-P-TS-003 The installation and the welding must be carried out by
qualified staff with experience in work with HDPE pipe materials.

Thermal expansion and contraction must be controlled as follows:

a) Ideally, the HDPE pipe must be installed at a temperature ranging
between 5 C and 7C design temperature indicated in the list of lines,
considering the season and time of day. The temperature can be adjusted
by circulating hot or cold air through the pipes to obtain the required
temperature. This is particularly important in the case of connections
between two fixed points.
b) Supports must be provided to prevent overloading on adjacent points of
c) The HDPE pipes installed on the surface or buried must be undulated and
anchored, as necessary, so that the heat expansion and contraction can be
controlled by lateral deflection. The level of undulation required for the
buried pipes shall be smaller than that required for the exposed pipes on
the surface, due to the smaller changes in temperature and in the thermal
mass of the ground. The buried pipes shall also require less anchoring
due to the natural anchoring power provided by the contact with the
d) To install an HDPE pipe on the surface between two fixed connection
points, sufficient pipe length must be added to allow for the contraction.
The extra length is calculated using the following formula:

L =0,00017 L (t1 - t2)

L =extra length, in meters, to be added to L
L =length, in meters, at room temperature at the time of installation
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t1 =room temperature at the time of installation
t2 =lowest temperature of the season in the area

Anchoring must be provided to prevent excess stress on the end of the HDPE
pipe and the on the connection to adjacent fixed tanks, equipment or piping.

Care must be taken to avoid damages to the casings and linings upon installing
the cased, lined pipes or rubber hoses.

4.11 Access and open/unobstructed spaces

The pipes must not interfere with the access to the valves or the equipment and
must not obstruct aisles or walkways. When access is required, the minimum
open/unobstructed spaces must meet the requirements contained in the General
Specification for Installation of field piping Systems No SPCC-PTM-P-TS-001
for this project.
Pipe installations that fail to meet these limits require the approval of the
authorized representative of SOUTHERN PERU. Furthermore, they must be
supplemented by suitable onsite security signs and markings.

4.12 Passage of pipes through walls

Penetrations in surfaces, walls and partitions to accommodate the pipes must be
carried out according to the instructions container in the drawings. The pasajes
must be sealed and covered after the installation with suitable materials existing
in the market, similar or equal to the HILTY products.

4.13 Specialties

The installation of special complementary items, such as, filters, special
couplings, valves, etc, must meet the manufacturers specifications with due
provision for access to operation, maintenance and removal.

4.14 Flanged joint

Flanged joints must be installed and anchored to obtain the exact alignment of
the holes for the bolts and an even, stress free contact with the total area of the

Forcing the pipe in order to tighten the joints shall not be allowed. The bolts for
the steel and cast iron flanges shall be tightened with a torque recommended by
the manufacturers of the packing used in the connection.

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The bolts for the valve flanges and special pieces made of FRP or plastic shall
be tightened strictly in accordance with the instructions of the manufacturers.

Inspect the gasket material for possible defects such as bents or creases.

Use logical sequence of bolt tightening to ensure even gasket compression, as
indicated in ASME B16.5, or by suppliers recommendations.

Prior to bolt-up, examine flange faces. Flange faces shall be in as-new condition,
and shall be wiped clean of any debris, excess oil, grease, and dirt. Do not
perform weld repairs on flange faces or flanges unless previously authorized by
Southern Peru authorized representative.

Inspect the studs and nuts. They should be of dirt and corrosion. The studs
should be straight and the threats free from nicks, burrs and chips.

Do not use washers or spacers to make up bolt length. Bolt lengths are specified
to prevent over sizing.

The calibration of torque wrenches and tensioners shall be checked against the
manufacturers specifications upon receipt. Any tools that are out of calibration
shall be rejected. A recheck f the calibration shall be made on a regular basis.
Any tool found to be out of calibration shall immediately be taken out of service
for repair. Frequency of calibration shall be recommended by the tensioner
manufacturer. All flanged joints secured with tools found to be defective shall be
rechecked with a properly functioning tool.

4.15 Valves

The valves, except for the valves of instruments, vents and drains must be
accessible for operation from the operating platforms. When indicated in the
project drawings, or where the installation of manual valves in inaccessible
places is necessary and practical, the valves must be supplied with extension
stems/rods or with hand-wheels with chains.

When extension rods are installed in valves subject to linear displacements by
heat expansion or contraction, these must include universal joints.

The primary isolation valves for the connection of manometers, etc. must be
installed as shown in the projects drawings.

The rods of the valves shall not be tipped/inclined below the horizontal position
unless otherwise specifically indicated in the project drawings.

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The globe valves must be installed with a line pressure under the seat. In the
vacuum service, the negative pressure must be on top of the seat.

The cone valves lined with soft rubber must be directed according to Attachment
1 to this Specification to prevent the accumulation of solids that may restrict the
movement of the cone.

All unidirectional valves must be installed with the flow arrow marked on the
body of the valve corresponding to the direction of the flow.

All the valves must be examined prior to their installation to check that they
meet the technical specifications.

4.16 Service stations, emergency showers and eyewash basins

The indoor and outdoor service stations, emergency showers and eyewash basins
must be installed according to detail drawing of the project.

4.17 As built drawings

A full and accurate record of all the unmet specifications container in the
projects drawings shall be marked in a reproducible set of documents that must
be kept both clearly and cleanly.

Modifications due to interferences must be approved prior to the installation and
recorded in the drawings. The routing pipe in the field and the pipe supports
must also be recorded as built by the installer.

The as built drawings must be submitted for the approval and acceptance of
the authorized representative of Southern Peru prior to their final issue.


5.1 Revision of procedures

Before beginning the work, all the welding procedures must be issued for review
and must include the records of the suitable qualification testing procedure
(PQR). The records of the qualification of welders must be available for the
authorized representative of Southern Peru at his convenience. The welding
work shall only be started when the representative has approved and authorized
their application in the project works.

Welder operators shall be tested by installer QC inspector to assure that his
welds will meet the requirements of specification.
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All tests shall be in strict accordance with the provisions of ANSI B 31.3 for in-
plant piping or API standard 1104 for long distance pipeline as applicable.

Two copies of welding procedures with copies of the Record of Qualification
Test Report shall be submitted to Southern Per representative prior to start of

The repair procedures that use welding must be issued for review.

The repair procedures must include:

a) The method to establish the type and size of the defect.
b) The methods used to eliminate the defect and the test performed to make
sure that the defect has been corrected.
c) The welding procedure used to re-solder and the non-destructive
examination methods (NDE) carried out to inspect the weld repair area
after performing the welding.

5.2 Welding processes

The welding processes listed below can be used, subject to the following

Gas Arc Welding (GMAW)

The range of transference due to short circuiting must be limited to:

1) Ferrous materials that do not exceed a nominal thickness of 7 mm
(1/4) and to austenitic steel and nickel based materials with a
nominal thickness of up to and including 5 mm (3/16).
2) Pipes butt welded on one side only, in flat or rotating positions
regardless of the thickness of the material.
3) Non-structural inserts when the welded material does not exceed
a nominal thickness of 7 mm(1/4 inches).
4) Welding of points, temporary inserts, couplings welded on both
sides and other applications in which the metal welding deposited
by the GMAW short-circuiting process is subsequently

5.3 Welding electrodes

The welding materials must be selected in such a manner that the deposited
welding metal is not significantly harder or more resistant than the base material.
Welding for couplings made of uneven ferrous material must match the
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resistance of the material of the lowest P-number groups contained in
Appendix A of Standard ASME/ANSI B31.3, Table A-1 Basic Allowance
Stresses in Tension for Metals.

The detailed engineering drawings shall indicate the electrode and type of
welding to be employed whenever welded joints/connections are required.

However, the installer must bear in mind that all the arc welded metals must be
welded using low hydrogen type electrodes in any of the following conditions:

a) In steels with a specified carbon content of over 0.30% or steels with a
resistance to tension of over 482650 Kpa (70.000 psi), or in ferrous steel
smelting repairs with SMAW welding.

b) For the materials of steel piping in group P-1 that require the use of
low hydrogen electrodes, only the butt can be soldered with AWS E6010
and E7010-A1 electrodes, respectively.

c) If the base material has been impact tested, the electrodes classified
under E6012, E6013, E7014 and E7024 must not be used to pressure
weld parts. However, these electrodes can be used in fillet welds in parts
without pressure of materials in group P-1. The storage, heating and
drying of coated electrodes, flux-coated electrodes and fluxes must meet
the recommendations of the manufacturer.

5.4 Welding requirements

All welding works must be protected from the wind, rain and other adverse
weather conditions that may affect the quality of the weld.

The surfaces to be welded must be free of incrustations, oil, grease, dust, paint,
galvanizing and other pollutants.

The passage of all the butt welds must be inspected by applying penetrating die.
The QC inspector of the installer shall be the person in charge of qualifying the
result of the test and shall authorize that welding be continued if the result is
correct. Otherwise, he shall order the work to be redone.

The thickness of each layer of individual welding, for all processes, must not
exceed 13 mm (1/2) for materials with a thickness of 32 mm (1-1/4) and more,
and 10 mm (3/8) for materials with a thickness of 32 mm (1-1/4) and less.

Welds that retain pressure must have two layers at least. The slag/clinker must
be fully eliminated before proceeding with the next layer.
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When double groove welding is used, the first step must be chiseled, sanded or
cleaned with the arc until the metal is totally clean before soldering a second

After cleaning with the arc, an inspection for magnetic particles shall be carried
out at the request of the authorized representative of Southern Peru.

Welding without beveling is prohibited. The procedures and good building
practices must be applied.

5.5 Preheating

The preheating temperature must meet the applicable codes, except for the
recommended minimum preheating temperatures which must be considered
mandatory. The preheating requirements must also be applied to the spot
welding and to the welding of temporary inserts. The preheating requirements
must also be applied to arc cleaning and to the cutting operations, except for the
steels of group P-1.

In addition to the requirements of the applicable code, the steels in group P-1
must have a minimum preheating temperature of 80C, for thicknesses that
exceed 38 mm (1-1/2).

Preheating must be established with fusion thermometers, contact pyrometers or
other appropriate equivalent means.

5.6 Labor, visual examination of quality and inspection

The welding layer must be even and without slag sediments, porosity and
damaging undercuts. Cracks and lack of fusion and/or penetration are forbidden.

In addition, the final welding layer must be basically free of rough formations,
uneven seams, high peaks or depressions. The marks left by the blows of the arc
at the beginning and at the end of the welds must be re-smelted with welding or
eliminated with emery. Welding with cracks must not be locally repaired. The
total length of the weld must be eliminated and the groove must be prepared
once again for new welding application.

The socket weld must have a light of 2 mm (1/16) minimum to 3 mm (1/8)
maximum, approximately, between the bottom of the socket to the end of the
pipe, prior to execution.

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The misalignment of the pipe couplings that were butt welded on one side only
must not exceed 2 mm (1/16) unless otherwise expressly approved by the
representative of Southern Peru solely for lines with a high flow speed.


Bronze and tin welds must be carried out by qualified staff according to the
recommendations of the manufacturer for the materials that are being welded.

The welding procedures must be issued and forwarded to the authorized
representative of Southern Peru for his review and approval prior to their


The electrical heating requirements will be appliance according design
specifications and drawings for steel piping..


The installer must prepare and present to the representative of Southern Peru for
approval thereof, of the cleaning procedures for each pipeline as relevant and
according to the design specifications to this effect. The installer is responsible
for the execution of these actions and the necessary equipment.

The pipes must be dry, totally clean and free of dust, slag and other loose foreign
material, before being mounted. The spools can be placed face down and banged
to remove the dust and other waste prior to the final thorough cleaning

Solvents shall be used to eliminate grease, oil or other foreign material. The
recommended solvents are acetone and trichloretane. Solvents with chlorine
used to clean stainless steel pipes must be immediately eliminated after cleaning
with potable water, rinsing oil, hydraulic or transmission oil.

The installer shall be responsible for the disposal of chemicals, washing water,
flushing oil, containers and the like.

The stainless steel pipes shall be brushed with clean stainless steel brushes that
have not been previously used in materials other than stainless steel.
The hot-rolled bends must be hand cleaned to fully remove the adhered sand.

Following chemical clearing and inspection, cleaned piping subject to prolonged
periods of storage, prior to installation, shall have all openings tightly sealed to
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protect against the possible entry of foreign matter, moisture, etc. until the entire
system is ready for operation. Flanged ends shall be sealed using tape and
polyethylene sheeting . Threaded or socket weld connections and butt weld ends
shall be tightly sealed with polyethylene or plastic plugs ( or cans) secured with
tape. Tape used for securing covers shall be of a vinyl waterproof type.

The method for the discharge of chemical products, rinse water, flushing oil,
containers and similar elements, must be issued and forwarded to the authorized
Representative of Southern Peru for approval thereof. Under no circumstance
shall the waste be discharged in the plant.

For PVC piping lines cleaning and flushing shall be according fabricator

8.1 Flushing of Steel pipelines

8.1.1. General Requirements

a) As an initial stage, all the pipe systems, including the lines for the
transportation of sulfuric acid, must be cleaned inside with air or steam
to remove the waste and other foreign matters.

b) For those systems that require flushing, they shall be flushed at speeds
that must not fall below the design speeds. The long vertical pipes must
be cleaned downwards. The main distribution heads must be washed
separately before washing the branch pipes. Flushing with water must be
carried out with clean water using the water spray of the hydrostatic test
whenever possible. The transmission and hydraulic oil pipes must be
cleaned with flushing oil.

c) The pipes upstream from the pumps or compressors must be washed
before the downstream pipes.

d) The downstream pipes, subject to the approval of the authorized
Representative of Southern Peru, can be washed or flushed using the
installed pumps or compressors. This equipment can be protected by
temporary suction filters during the cleaning process and the initial tests
if the conditions so require.

e) The flushing of any element of the system shall be considered completed
when the eye-inspection of a sample of one quarter of a gallon of
flushing water appears to be clean and with no suspended material.

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The pipes must not be connected to the equipment until flushing has
been completed.

The use of fresh water obtained from the ground shall require the
approval of the authorized Representative of Southern Peru. The
Installer must schedule the date and time prior to the execution of the
works to make the necessary arrangements.

8.1.2 Suction pipes of compressors and vacuum pumps

a) The suction pipes of compressors and vacuum pumps must be carefully
cleaned to remove incrustations and all kinds of foreign material.
Depending on the conditions, suction filters may be required.

b) The suction pipes of the centrifugal compressors must be blown or
cleaned by hand until they are completely clean prior to attaching them
to the respective machine.

8.1.3 Drinking water supply pipes

a) All the drinking water supply pipes must be flushed and chemically
disinfected according to AWWA C-601.

8.1.4 Lubricant, hydraulic and transmission oil pipes

Prior to the referred cleaning or flushing process, all the pipes of these
systems must undergo a pickling (chemical wash) according to the
following procedure:
-Degrease to fully remove the protective coating.
-Clean with sulfuric acid at 5% to remove all foreign substances inside
the pipe.
-Neutralize, rinse and fully remove the Pickling solution.
-Dry carefully.
-Protect the interior of the pipe with a corrosion-resistant protector
approved by the authorized Representative of Southern Peru.

a) The stainless steel pipes for lubricating, hydraulic and transmission oil
systems must be cleaned with a mildew inhibitor washing oil until there
are no particles of dirt, metal or any other type of material. Washing
must be carried out for at least one hour or until no waste is observed in a
filtering cloth of 30 nominal microns.

b) After cleaning, the system must be pressure tested, using flushing oil as a
test fluid.
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c) The flushing oil must be emptied and all the equipment, catch basins,
filter, etc., cleaned.

d) Immediately after emptying, the operating oil must be circulated in the
system until all traces of flushing oil have disappeared.

e) The circulated oil must be emptied and the system must be immediately
filled with fresh operating oil. The system must be sealed ready to

f) Disposal of chemicals: the Installer shall be responsible for the safe
storage and disposal of all the flushing oils, chemical washes and
containers. In these cases, the counseling of the Department of
Environmental Services shall be provided through the authorized
Representative of Southern Peru.

8.1.5. Pipes for sulfuric acid

After the initial cleaning stage, the pipes of the sulfuric acid system shall be
flushed with water prior to their installation. Once they have been installed they
shall be hydrostatically tested. Upon completion of the hydrostatic test, the
entire system shall be dried with dry air.

8.1.6. Control vales and instruments

The control valves and instruments must be flushed or removed as follows:

a) Control valves with gate and bypass valves: Remove the valve, open the
bypass valve, close the gate valves and wash. Open the gate valve
upstream and wash. Close the gate valve downstream and wash for five

b) Control valve without a gate or bypass valve: remove the valve. Install a
spool and wash.

c) Magnetic Flow Gages: wash them completely.

d) Positive displacement gages: Remove the gages. Clean as in point b).

e) Rotameters, flow regulators, solenoid valves, pinch valves: remove the
instrument. Wash as in point b).

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8.2 Procedures for approval

a) The proposed sector to be washed and the flushing or cleaning
procedures must be communicated to the authorized Representative of
Southern Peru for approval prior to proceeding thereon.
b) The records of the washing and rinsing procedures carried out must be
inspected by the QC of the installer and approved and signed, after which
they shall be filed.

8.3 Evacuation of cleaning agents and chemical products.

The Installer is responsible for the safe elimination of flushing oils, chemical
cleaning products (pickling solutions) and containers thereof. The Department
of Environmental Services shall provide counseling through the authorized
Representative of Southern Peru.


The carbon steel pipes that have no thermal isolation shall be painted and
according to specification No SPCC-PTM-C-TS-006 Shop priming and
painting the stainless steel pipes and plastic pipes shall not be painted.


10.1 General
The installer contractor shall have in effect at all times, a quality control
program, which clearly establishes the authority and responsibility of those
responsible for the quality system. Persons performing quality control functions
shall have sufficient and well-defined authority to enforce quality requirements
that initiate, identify, recommended, and provide solutions to quality problems
and verify the effectiveness of the corrective action.

A copy of the installer contractor quality control program shall be submitted for
Southern Peru review and approval prior to work starting.

The quality control program shall include procedures, instructions, and QA
systems to ensure that assigned field construction, fabrication, assembly,
installation, field purchased materials and services, field engineering,
workmanship, and other related services conform with the specified codes,
approved design engineering specifications, design drawings, and other
contractual, jurisdictional, and legal requirements.

Southern Peru shall examine and inspect the final product to ensure that installer
contractor quality criteria have been met.
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Prior to inspection, the installer must remove all the provisional installations,
scaffolding, frameworks, wedges, belts and other materials used in the assembly,
maintaining only the minimum required to allow access for the inspection.

The finished systems of pipes must be eye-inspected to check that they have
been completed finished: the installation of the packing, the proper installation
of the valves, suitable supports, the control valves and instruments have been
correctly installed, etc. To this effect, the P&ID drawings of the project, as
issued for the construction, must be used.

The QC of the installer shall have the updated QC documents readily available
of all the applications during the construction process (mounting and


The pipes shall be identified based on Specification N SPCC-PTM-C-TS-006
Shop priming and painting to this effect.

The carbon steel pipes without exception must be fully painted and signaled
according to the color code and name of the fluid that identifies them. In
addition, arrows indicating the direction of the flow must be painted every 6m or
the most convenient length according to their plant layout.

Colored painted rings must be placed at intervals of no less than 6m or more
than 15 m, depending on the position and configuration and in all the changes of
direction, including the branches.

The identifying color painted rings must be 50mm wide with a spacing of 50mm
between the bands for multiple band codes.


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

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

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

No lines shall be hydrostatically tested to less than 50 psig. Except sanitary lines
and drains. Sewer and drain lines shall be tested a minimum hydrostatic head of
10 feet.

The following lines may be tested pneumatically

Instrument air lines
Compressed air lines for general service
Nitrogen gas lines .

The above lines shall be tested with air at pressure equal to at least 110 percent
of the operating pressure.

The pneumatic test pressure shall not exceed 150 psig. Lines being
pneumatically tested shall be brought up to final test pressure in easy stages to
avoid vibration . All joints shall be swabbed with a leak detecting compound.

Personnel responsible for testing shall record the test pressure applied to each
line using the attached form Pressure Test Record witnessed and signed bay
QC constructor.

Closed valves may be used at the extremities of the systems to be tested at the
discretion of constructor.

Line test pressures, established in accordance with the specification No SPCC-
PTM-P-TS-001 or Piping Line Lists, shall not include any major equipment.
However, it is preferred to test exchangers and/or vessels simultaneously with
connected piping, provided the test pressure used is not higher than that
permitted for the equipment.

Orifice plates, which interfere with filling, venting and draining, shall be
removed prior to testing. Where expansion joints are used in piping, they shall
no be subjected to test pressures higher than their design test pressure. Other
pieces of equipment, such as flame arrestors, filters, and instruments, which do
not have test pressures indicated, shall not be included in the tests.

Pressure parts of instruments together with piping connecting to main pipe lines
or equipment shall be tested at the same test pressures as the main piping or

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Pressure gauges shall not be subject to pressures in excess of their scale ranges.
Where lines to which they are connected receive a higher hydrostatic test
pressure, the gauges shall be removed and their connections plugged. After the
test, pressure gauges shall be reinstalled.

Prior to filling a system for testing, all pipe lines shall be cleaned thoroughly.

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

Care shall be exercised in testing so the applied pressure is limited to that
portion of the system being tested.

Pressure relief and thermal expansion relief valves shall be excluded from the
pressure tests. Blinds shall be installed adjacent to their inlet and/or outlet
flanges during tests. Screwed relief valves shall be removed and the connections
plugged during the test.

Lines containing check valves shall have the source of pressure located upstream
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 discs popped

Control valves shall be set in the wide open position.

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.

Care shall be exercised in order to prevent concentration of excessive loads on
the support structure.

Retesting of lines, after repair, shall be done at the pressure originally specified
for the test.

After completion of hydrostatic testing, temporary blanks and blinds shall be
removed and lines shall be completely drained. Valves, orifice plates, expansion
joints, etc. shall be reinstalled. After the lines have been drained, temporary
supports shall be removed.

Lines pneumatically tested shall be kept under test pressure for not less than one
hour, without a 5 % loss in pressure. If loss exceeds 5 % in one hour leaks shall
be repaired. After repairing leaks, retest the line at the pressure originally
specified for the test.

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EQUIPMENT NUMBER ________________________AREA_________________________






FLUSHING MEDIA____________________________________________________________

PRESURE________________________________FLOW RATE_________________________

TEMPERATURE___________TIME START______________TIME FINISH______________

SCREEN SIZE______________________FILTER SIZE_______________________________

SPECIAL CONDITIONS________________________________________________________





PERFORMED BY_________________________STARTUP ENGINEER_________________

WITNESSED BY___________________________________________

DATE _____________________________

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TYPE TEST : PNEUMATIC________________________

STATIC ________________________


DRAWING NUMBER ATTACHED ______________________________________________

TEST DESCRIPTION __________________________________________________________



OPERATION PRESSURE________________ TEST PRESSURE______________________

TIME START__________________________ TIME FINISH _________________________

TEMP START ________________________- TEMP FINISH _________________________

LEAK RATE _________________________ FINAL TEST PRESSURE _______________




PERFORMED BY _____________________STARTUP ENG___________________________

WITNESSED/ACCEPTED FOR OWNER __________________________________________