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 600
Tucson, Arizona 85705-1799 Date: April 2008
REV 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, REVISED
COLOR CODE TABLE 1A , 1B
3 08/15/11 TG APP RC UPDATED TABLE 1A AS NOTED


DISTRIBUTION A B C 0 1 2 3 4 5 6 7 8 9 10
Client 03/12 2/7
Procurement
Field
Internal 02/28

Note: Signed originals on file
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 2 of 34

INDEX
PAGE
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
15 CHEMICAL CLEANING AND PICKLING 24
16 PIPE SUPPORTS 26
17 PAINTING 27
18 LIST OF ATTACHMENTS 27
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 3 of 34
1 SCOPE

This General Criteria Specification covers minimum requirements for the installation of
all 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 standards
that 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, Inc
Vendor/Contractor: Contractor hired to perform the work and installation.

All material, fabrication, assembly and installation, where applicable, shall
conform 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 limit
boundary).
B31.8 - Gas Transmission and Distribution Piping Systems
(For fuel gas systems outside plant battery limits)
B31.11 Slurry Transportation Piping Systems
(For slurry piping systems within plant boundary limits)

API American Petroleum Institute Standards

ASME American Society of Mechanical Engineers, Boiler and Pressure Vessel
Code
Section VIII, Division 1 - Unfired Pressure Vessels
Section IX - Welding and Brazing Qualifications

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 4 of 34

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 de
Tuberas Para Trasporte de Fluidos en Estado Gaseoso o Lquido
en Instalaciones Terrestres y en Naves)

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

All applicable Peruvian and Local Laws and Regulations.

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


3 PIPING IDENTIFICATION

Piping Designation is shown in Drawing No.000-PI-T-001, P & I D Piping Legend and
General Specification 000-GD-P-006, Piping Design.

Installed piping shall be labeled in accordance with ANSI A13.1, Scheme for the
Identification of Piping Systems. Intervals on straight pipe runs shall be 12 m maximum
between labels or at designated locations near doors, etc. Legends shall be applied
close to valves or flanges and adjacent to changes in direction, branches, and where
pipes pass through walls or floors. The labels as referred to by ANSI A13.1 shall be per
3
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 5 of 34
attached Appendix I of this specification, corresponding to the commodity code shown
on the line designation. Labels shall be in Spanish.


4 GENERAL REQUIREMENTS

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

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

Buyer will issue piping isometric drawings for all areas. Vendor may prepare fabrication
isometrics at his discretion to facilitate piping fabrication and installation.

Piping materials and branch reinforcements shall be in accordance with General
Specification 000-GD-P-007, Piping Material Classes. All piping materials when
received 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 mm
thick for 350 mm NPD and larger.

Internal burrs and excess weld material shall be removed from the upstream run of all
orifice plates.

Gaskets shall be new, clean, and dry, and shall not be coated.

Flange facings shall be clean, dry, and shall not be coated.

All weld neck flanges shall have the same bore as the inside diameter of the adjoining
pipe or fitting.

Break flanges, unions, or break couplings that are provided for dismantling lines at
equipment or maintenance access to nearby equipment will be shown on the piping
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 6 of 34
drawings. Vendor may install additional break flanges, unions, or break couplings with
prior written approval from the Buyer.
Flange bolts shall have their threads lubricated with molybdenum disulfide, or an
equivalent lubricant. Lubricant used in piping for oxygen service shall be oxygen
compatible.

Bolt holes shall straddle the vertical centerline, or radial centerline, unless shown
otherwise on the drawings.
Where piping requires welding interface with piping supplied "By Others", the materials
being joined shall have weld compatibility. Flanged connections may be used as
necessary.

If welding fittings corresponding to pipe wall thickness are not available, thicker fittings
may 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 to
equipment or to instruments.

No close nipples shall be used.

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

High points in all lines which will be hydrostatically tested shall be provided with a vent
for 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 the
funnel.

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

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

All unused openings in process equipment shall be closed either with a plug, nipple and
cap or blind flange, unless otherwise noted on the drawings.

Pipe threads shall be made up with a lubricating paste sealant or tape, except those for
oxygen service. Threaded joints in oxygen service piping shall be solder-sweated.

Threaded joints to be seal welded shall be made up dry. The weld shall be a smooth
transition and shall cover all exposed threads.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 7 of 34
Temporary strainers shall be provided where called for in the drawings. No temporary
strainer shall be permanently removed from its hook-up until all internal foreign materials
have been trapped and thoroughly removed from the piping system. Temporary
strainers shall be removed only after the piping system has been accepted by the Buyer
and the Owner and prior to placing the piping in normal service. Cone strainers shall be
installed in spool with flanged ends for ease of removal.

All piping supports shall be designed in accordance with the seismic and wind
parameters/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 subject
to 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 manufacturers
recommendations.


7 WELDER QUALIFICATION AND PROCEDURE APPROVAL

Welding operators shall be pre-qualified to ensure that welds will meet the requirements
of this specification. All tests shall be in strict accordance with the provisions of Section
IX of the ASME Boiler and Pressure Vessel Code, or API Standard 1104, where
applicable.

Three copies of welding procedures with copies of the "Record of Qualification Test
Reports" shall be submitted to the Buyer prior to start of welding.

Buyer shall approve the welding procedure before the start of welding.


Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 8 of 34
8 FIELD WELDING CARBON STEEL PIPE

The ends of pipe and welding fittings shall be beveled in accordance with the ASME
B16.25. Preparation of ends by machining is preferred. Fusion and penetration shall
be obtained without "icicles" or drip through at the root.

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

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 the
nominal inside pipe diameter for accurate internal fit-up.

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

All welding shall be done by manual metal arc process, automatic submerged arc
process, metal inert gas process (MIG), tungsten inert gas process (TIG), or a
combination of them. The root pass on all welded pipes for oxygen service shall be
made 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 or
ground 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 and
physical 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 shall
deposit weld metal of chemical composition and physical properties compatible with the
base metal.

Filler electrodes and wires used with the MIG and TIG processes shall deposit weld
metal of chemical composition and physical properties compatible with the base metal.
The shielding gas shall be suitable for the process.

Welds joining carbon or low alloy steels to austenitic stainless steels shall be welded
with E309 or ER309 type filler metals.

Note: Welding carbon steel or alloy steel to austenitic stainless steel is allowed
only on specific written approval. It is not allowed on vessels and piping carrying
corrosive fluids or at elevated temperatures.
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 9 of 34

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 tungsten
inert 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 metal
applied for each pass shall not exceed 5 mm. Slag or flux shall be removed after each
pass, 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 in
accordance with the applicable ASME Design Code (B31.1 or B31.3) as noted on each
Piping 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 to
pressure parts. There shall be no substitution of materials without prior written
approval from the Buyer.

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

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

Do not use iron or steel tools and handling fixtures. Only stainless
steel wire brushes or abrasive disks and wheels and other grinding,
finishing, or cleaning equipment which have not been used on iron
and steel may be used.
Alloy 2205 material shall not be exposed to foot traffic. Do not place
or drag Alloy 2205 materials on floors that may be contaminated with
iron.
Separate all Alloy 2205 fabrication from any steel fabrications.
Any steel grinding, cutting, and blasting operations shall be done
separate from Alloy 2205 operations.
Bending, shaping and forming equipment and dies shall not have
been used on iron or carbon steel. If they have, they must be
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 10 of 34
cleaned to eliminate all free iron contaminants. It is acceptable to
use bending, shaping and forming equipment and dies ordinarily used
for austenitic stainless steel or nickel base alloys; however, Alloy
2205s much higher hardness and strength must be accounted for.

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

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

Alloy filler electrodes used with the automatic submerged arc process and the
flux or melt used shall deposit weld metal of chemical composition and physical
properties similar to the base metal. Alloyed fluxes or melts in combination with
mild steel or alloy wires shall not be used. Filler metal shall be ERTi-1 for
Titanium 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 lower
alloy 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 thickness
of 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 and
spatter metal on all surfaces. Brushes, chisels, and other tools used for
cleaning shall be of stainless steel material.

In Titanium welding, the minimum preheat temperature is 15C and maximum
interpass temperature is 93C. In Duplex 2205 welding, a minimum
recommended 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
trench, except at joints where clearance is required.

Underground piping shall be protected from corrosion in accordance with
General Specification 000-GD-P-007, Piping Material Classes.

All new buried/underground piping shall have both tracer lines and warning
ribbons as follows:

Color coded utility warning ribbon shall be placed 305 mm above the top
of the buried pipe;
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 11 of 34
Bare tracing wire/lines shall be placed 152 mm above the top of the
buried 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) shall
not 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 minimum
below bottom of pipe and back-filled with granular material for level or slight
slopes, or sand mixed with clay for steep slopes and compacted to form the
bottom of the trench. Backfill, sand bedding, and compaction shall be in
accordance with General Specification 000-GC-S-001.

Unsuitable material in trenches - such as expansive soils, organic, or loose
material - shall be removed from the underside of pipe(s) and for a width of not
less than one-diameter of the outermost pipe on each side of the pipeway. The
space shall be back-filled with suitable material, as described below.

Piping shall be placed on a minimum base of 150 mm of granular bedding
material of minus 9.5 mm size. After installation and testing, additional bedding
material shall be placed around and over the pipe until a minimum of 6 inches
over 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 accordance
with General Specification 000-GC-S-001.

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

10.3 Laying Of Sanitary Sewer Piping

The pipe shall be laid upgrade without break. Pipe shall be supported for the full
length by the bottom of the trench, except at the joints, where joint clearance
shall be provided.

The pipe shall be fitted and matched when laying so that there are no shoulders
or unevenness along the lower half of the pipe.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 12 of 34
The trench shall be kept free of water at the time of laying pipe or joint making.
Saturated material shall be removed from the trench and replaced with suitable
material.

Whenever work ceases, the end of the pipe shall be securely closed with a tight
fitting cover.

The interior of the pipe shall be kept clean and free of all dirt and foreign material
at the completion of work.

The minimum slope for sewer piping shall be one percent or as indicated on the
Buyers drawings.

10.4 Jointing

Mechanical joints, push-on joints, and PVC gasketted bell and spigot joints shall
be made up in accordance with manufacturer's recommended procedures.

Equipment for driving the pipe in place shall be approved by the Buyer. After the
joint is placed the position of the gasket shall be checked.

10.5 Inspection and Testing

Prior to back-filling, each section of pipe shall be hydrotested as specified on the
Piping Line List and maintaining pressure for at least 30 minutes with no
pressure drop.


11 OXYGEN PIPING

11.1 General

Installation shall be in accordance with ANSI B31.3, B31.8, and CGA Standards.

Piping shall be stored and handled carefully to prevent contamination of the pipe
interior, and to prevent damage to temporary closures and the exterior protective
coating.
Valves, instruments, and in-line specialty items shall be purchased "cleaned for
oxygen service". If the factory seal is destroyed prior to installations, the item
must be inspected and re-cleaned.

Refer to the Material Safety Data Sheets (MSDS) for the chemical properties,
hazards, safety equipment, and emergency specifications applicable to the
specific cleaners and solvents utilized.

Oxygen is a colorless odorless gas that will, in concentrations above 23.5% by
volume, vigorously accelerate combustion. Extreme care must be taken to
prevent unintentional exposure to enriched oxygen environments.
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 13 of 34

Oxygen concentrations below 19.5% by volume reduce the capacity to sustain
life and may cause asphyxiation. Extreme care must be taken to prevent
exposure 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 level
specified in Section 11.4. Cleaning methods may include one or a combination
of the following:

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

Slagblasting
Only dry, oil-free air shall be used for blasting. Blasting material shall be
glass or slag blast media and shall be clean and free of hydrocarbon
contamination. Coal slag material, Black Beauty is prohibited for use as
a blasting agent for oxygen service cleaning.

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

Brushing
Note: Brushes with carbon steel bristles are only permitted to be used on
carbon steel. Stainless brushes are preferred. Copper, brass, or bronze
brushes may be used.

Blowing
After any mechanical cleaning, the components or systems must be
cleaned by blowing, swabbing, or vacuuming.

Hand Wiping
Hand wiping is a mechanical cleaning method using a clean, lint free
cloth to wipe only on small select areas on components or systems.
Readily accessible surfaces may be cleaned using only a Quiltec 1
Wiper, Part Nos. QTI99 or QTI1212 or a Polywipe-C Heatseal Wiper,
Part Nos. PCHS99 or PCHS1212 (available from Contec Corp., P.O. Box
530, Spartanburg, SC 29304), which is moistened with a cleaning
solution or solvent.

It shall only be used as spot cleaning for large components and only
after other cleaning methods have been employed. It may be used as
the sole cleaning method for small components such as tubing fittings,
tubing elbows, tubing connectors, etc.
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 14 of 34

Swabbing
Swabbing is a mechanical cleaning method using a clean, lint free mop to
clean areas on components or systems which are too large to clean by
hand wiping. Readily accessible surfaces may be cleaned using only an
Edgeless Mop, Part No. ELMOP (available from Contec Corp.) which is
moistened with a cleaning solution. Polyethylene pales or buckets are
acceptable for use with the aqueous cleaners. Any pail or bucket used
for swabbing must first be cleaned with the cleaning agent to be used.
The material of construction of pails and buckets must be compatible with
the cleaning agent to be used.

b) Chemical cleaning, including the use of solvent or alkaline solution for
grease removal, acid-pickling (de-scaling), passivating, de-rusting, bright-
dipping, solvent or hot detergent flushing, immersion, spraying and/or
wiping.

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

Wherever possible all piping shall be of welded construction, except at
connections to valves, meters, etc., where threaded or flanged joints are
required.

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

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

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

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

Workbenches shall be clean, free of oil, dirt, grease, etc.

All fit-up and assembly of each pipe spool, fitting, etc. shall be inspected to
ensure that cleanliness required for the oxygen service specified in Section 11.4
was maintained.

The first two production welds and ten percent of all other welds shall be
radiographed. Radiographs shall be interpreted by qualified technicians (Level 2
minimum per American Society of Non-Destructive Testing - Recommended
Practices SNT-TC-IA).
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 15 of 34

A solvent rinse pail shall be available for washing bolts and nuts to remove all oil,
dirt, or grease just prior to installation. Pails must be cleaned and inspected with
a UV light before use. Gaskets shall be cleaned if they are not individually
packaged or if the package seal is broken and contamination is suspected.

If piping is not being worked on, all open pipe ends shall be closed with a
securely fastened plastic bag, a hard board cover, commercial pipe plug, or
other similar method.

11.2 Sequence of Installation Operations

The piping system shall be assembled without installing valves, strainers,
orifices, meters, instruments, or other components of like nature. Pre-cleaned
flanged spools shall be installed in their stead. Locally mounted instruments and
instrument tubing shall not be connected.

The system shall be pressurized and leak tested as outlined in Section 11.3.

All piping, instrument taps, drains and vents shall be vigorously blown down,
using residual test gas or added purge gas. Gas shall be oil free air or nitrogen

The system shall be completed, installing the components, instruments, tubing
and tie-ins. If the system is not to be put into immediate service, it shall be put
under 10 psig minimum pressure of dry oil-free nitrogen.

11.3 Testing Procedure

Testing shall be performed in accordance with the applicable sections of ANSI
B31.1, B31.3 or B31.8.

Dead weight calibrated and certified pressure gauges shall be installed at the
inlet and discharge ends of the piping.

The pressure shall be brought up to that required for testing, slowly so as to
avoid inducing vibration.

The test pressure shall be held for a minimum of one hour. The pressure shall be
checked periodically during the test.

Any pressure loss shall be cause for rejection.

Should pressure loss occur, all joints, connections, etc. shall be tested with a
concentrated soap or detergent solution or a commercial leak test solution such
as "Snoop Leak Detector" to locate the leakage.

After all leaks are repaired, the system shall be re-tested as described above.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 16 of 34

11.4 Required Cleanliness Level

Accessible significant surfaces must be free of contaminants visible to the naked
eye when viewed under bright light. A final check of absence of oil and grease
should 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, or
loose 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 weld
spatter.

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 given
below which applies to the particular item. Parts, which will be inaccessible to
inspection after assembly, must be inspected prior to assembly. If inspection
reveals the presence of any contaminants, the item must be re-cleaned. Usually
wiping the contaminated area with a clean cloth moistened with an approved
solvent will adequately re-clean the area. Persistent rejection requires a
reevaluation of the cleaning techniques. An inspection log shall be established
and maintained.

a) Direct Visual Inspection: This method shall be used to verify the
cleanliness of an item with easily accessible surfaces. Look at or in the
item under bright white light to detect the presence of visible grease or oil
films and particulate matter, such as filings, chips, loose or loosely
adherent rust or mill scale. If any contamination is observed, the item
must be re-cleaned.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 17 of 34
Note 1: A light film of rust is acceptable. The Steel Structures Painting
Council Pictorial Standard B Sa 2 (ASTM D-2200-67) shows
an 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 AU
wavelength ultra-violet (black) light. If a bluish-white fluorescent blotch,
smear, smudge, or film is present, re-clean the item. Typical acceptable
models 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 a
large surface area. Wipe the item or at least one square foot of its
surface, 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, the
surface 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 is
acceptable (see also Note 1).
c) Solvent-Color Test: This method should be used to check the cleanliness
of 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 solvent
with a pint jar of unused solvent by holding both up to the light and
viewing them simultaneously through the side. There should be few
suspended 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

A test used to check for the presence of hydrocarbons or cleaning
residue. If any odor is detected, then the oxygen service component or
system must be re-purged with dry, oil-free air or nitrogen until no odor is
detected.

For components and systems being purged, stand a sufficient distance
away from the exiting gas stream, so that only uncontaminated air may
be inhaled.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 18 of 34
Take three (3) deep breaths.

Then, with your lungs full, place your clean, ungloved and cupped hand in
the gas stream. Bring your cupped hand to your nose and sniff your
hand. 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 opening
of the component or system to your nose using your clean, ungloved and
cupped hand. Sniff your hand; if no odor is detected, then directly sniff
the opening of the component or system being tested. An acceptable
test shall e one in which no odor is detected.

If at any time during this test an odor is detected, the system or
component 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
Immersion
30 minutes
2 4 hours
Overnight
Grease & Carbon
Light
Moderate
Heavy

1:4 1:20
1:2 1:10
1:1 1:2
Ambient to 43
o
C

Immersion
1 4 hours
Solidified Greases 1:1 1:2 Ambient to 43
o
C

Immersion
30 90 minutes
Gelled Oils 1:1 1:5 Ambient to 43
o
C
Immersion
4 hours overnight
Specialty Lubes 1:1 1:2 Ambient to 43
o
C

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

WARNING: DO NOT HEAT ANY CONCENTRATION OF A CITRIKLEEN HD
CLEANING SOLUTION ABOVE 49
o
C.

Prepare a cleaning solution by diluting the cleaner as specified in Table 2 and
use at the temperature indicated for the method of application.

Replace the Citrikleen HD solution when the cleaning efficiency has diminished
based upon subsequent inspection of the components being cleaned.

All components and systems cleaned with Citrikleen HD must be rinsed with
ambient clean water immediately and dried with oil free air or nitrogen.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 19 of 34
Note: Rinsing effectiveness is improved if warm (approximately 49
o
C F) clean
water is used.

Citrikleen HD residue DOES fluoresce under ultraviolet light. If any cleaned
component or system fluoresces, the oxygen service component or system shall
be 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 material
compatibility.

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 the
formation of surface rust. Drying may be accomplished using dry, oil-free air or
nitrogen, applying heat directly to the components and systems, blowing with a
fan or exposing components and systems to direct sunlight.

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

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

Interior surfaces of components or systems cleaned with solvent must be blown
dry using dry, oil-free air or nitrogen, applying heat directly to the components or
systems, blowing with a fan, or exposing components or systems to direct
sunlight. All traces of cleaning solvent odor must be removed from the
component or system by the drying process used.

11.8 Documentation Requirements

All cleaning and inspection of components or systems used in oxygen service
must be suitably documented. The attached form shall be used and filled in as
follows:

The following must be filled in:

a) Section I Required Information

Quantity (normally 1, unless multiple valves with same tag)
Component Descriptive name of component (value or line number)
Manufacturer (if fabricated pipe, write KIC)
Model or Line Number
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 20 of 34
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 the
inspection (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) for
that job.

Upon completion of the job and release to operational control, all oxygen service
cleaning/inspection documentation shall be transferred in the turnover package.


Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 21 of 34
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 upon
completion of construction work but before insulation at joints is applied.

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

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

Pressure gauges and pressure parts of instruments together with piping
connecting to main pipelines or equipment may be tested at the same test
pressures as the main piping or equipment provided that the test pressure does
not exceed 80% of the instrument scale range. If test pressure is more than
80% of scale range, the instruments shall be removed and their connections
plugged. Reinstall after test.

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
propped open.

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

Orifice plates, which interfere with filling, venting and draining, shall be removed
prior to testing. Where expansion joints are used in piping, they shall not be
subjected to test pressures higher than their design test pressure. Other pieces
of equipment, such as flame arresters, filters, and instruments, which do not
have test pressures indicated, shall not be included in the tests.

Closed valves with plugged terminal may be used at the extremities of the
systems to be tested at the discretion of Aker Solutions authorized
representative.

Line test pressures are established in accordance with General Specification
000-GD-P-007 and the Piping Line List. Major equipment which is pressure
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 22 of 34
tested independent of piping systems shall be excluded from the line pressure
test. However, simultaneous test of exchangers and/or vessels with connected
piping may be performed provided that the test pressure used is not higher than
that 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 Section
11.0 for desired cleanliness for oxygen service.
Water for hydro testing stainless steel piping shall not contain more than 50-PPM
chloride.

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

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.

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 sanitary
lines and drains. Sewer and drain lines shall be tested at a minimum hydrostatic
head of 3 m.

Re-testing 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.

12.3 Pneumatic Testing

The following lines may be tested pneumatically:

a) Instrument air lines
b) Compressed air lines for general service

These lines shall be tested with air at a pressure equal to at least 110 percent of
the design pressure.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 23 of 34
The pneumatic test pressure shall not exceed 1034 kPag. 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.

Lines pneumatically tested shall be kept under test pressure for not less than
one hour, without a loss in pressure. Repair any leaks and retest again at the
pressure originally specified for the test.

12.4 Pressure Test Record

Personnel responsible for testing shall record the test pressure applied to each
line using the attached form "Pressure Test Record," witnessed and signed by
Aker Solutions.

12.5 In Service Test

In-service test is primarily for Tie-ins to existing piping systems and shall be
performed on all Category D fluid piping. This may also be applied to other
piping systems contingent to Owners approval.


13 TEMPORARY PIPING

Temporary piping may not be shown on the Buyers drawings. However, Vendor may
be required to fabricate, install and possibly salvage temporary piping systems
necessary for the completion of the project. Temporary piping shall comply with the
requirements set forth in General Specifications 000-GD-P-006 and 000-GD-P-007.

All temporary piping shall be subject to Buyers inspection, suitable for the service
required and not be a safety hazard.


14 MECHANICAL CLEANING

All lines (see Section 11.0 for Oxygen piping requirement) shall be cleaned by flushing
with water until free of dirt, grit, welding slag, and other foreign materials. The line shall
be drained. Low-points and pockets shall be freed of any trapped water or debris and
the line air blown until dry.

Temporary strainers shall be installed to protect in-line instrument and pumps during the
initial operation.

Lines for water service need not be dried.

Clean fresh water shall be used for flushing.

Potable water shall be used for flushing oxygen lines, see Section 11.0.
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 24 of 34
15 CHEMICAL CLEANING AND PICKLING

Vendor shall submit MSDS (Material Safety Data Sheets) for all chemicals used in
cleaning the pipelines. The use and disposal of chemicals used in the cleaning shall be
coordinated 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 to
assure complete circulation and elimination of dead ends or branches, which can cause
gas traps.

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

Prior to chemical cleaning, carbon steel pipe spools shall be mechanically cleaned as
specified 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, oil
reservoirs, instruments, valves (except where valve materials are resistant to the
chemical 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 is
less, minimum through the piping.

All solutions, during the re-circulation sequences shall be filtered through the utilization
of 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 cleaning
carbon steel. This procedure shall include, but not necessarily be limited to these
requirements alone to achieve the desired intent of this procedure. All referenced
chemicals shall be considered on an "or equal" basis. Exceptions to this specification
may be made with written approval by the Buyer.

15.1 Degreasing

Not Applicable for this Project.

15.2 Rinse or Purge

Subsequent to the degreasing operation, flush the system with filtered fresh
water until a pH of 6 to 8 is achieved as indicated on Hydrion paper or
equivalent. Alternatively, purge system with dry air, in lieu of rinsing with water.
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 25 of 34
15.3 Pickling

For pickling of carbon steel piping, especially where system valves are included
in the operation, it is desirable to utilize an inhibited phosphoric acid material
readily 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 manufacturers
recommended concentration, temperatures, and time duration or until the
desired pickle is achieved as evidenced by visual observation.

The duration of the application shall be of sufficient length to give greater than 5
micron 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 is
achieved 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 the
system with a mixture of 0.25% by weight Disodium Phosphate and 0.50% by
weight Sodium Nitrite.

Circulate the mixture at 82C for 30 minutes and flash-dry by removing from the
system 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
minutes.

Ferrous valves containing non-ferrous alloys such as brass, bronze, or white
metal shall be disassembled. The ferrous parts of the valves shall be cleaned as
outlined above.

Non-ferrous valves and valve components shall be scrubbed with, or immersed
in, a hot 82C to 93C solution of TSP, mixed in the proportions of one part TSP
to three parts of water (by weight), for fifteen to twenty minutes.
Following chemical cleaning and inspection, cleaned piping subject to prolonged
periods of storage, prior to installation, shall have all openings tightly sealed to
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 26 of 34
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.


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 through
000-DW-P-122, unless shown otherwise.

Insulated piping 50 mm NPD and larger shall rest on pipe shoes, saddles, or other
adequate means of protecting insulation. Shoes for carbon steel pipe shall be welded to
the piping. Shoes for alloy pipe, galvanized pipe, and plastic pipe shall be welded to
carbon 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 be
used.

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

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 indicated
on the piping drawings.

All structural steel members shown are specified as ASTM A36 standard. If non-ASTM
standard members are substituted, an equivalent may be used with approval by the
Buyer.

Commercial parts called for on pipe support drawings are referred to specific
manufacturer and catalogue number. Equivalent parts by other manufacturers may be
substituted upon receipt of written approval from the Buyer.

Welding symbols shown on drawings conform to AWS Code.

All pipe anchors and intermediate supports shall be of the bracket, tee, framed-bent, or
equal type, made of steel, designed, braced, and installed to withstand all forces
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 27 of 34
imposed upon them by the expansion of pipe, weight of pipe and contents, wind
pressure etc. Lines shall not be extended by means of a dead-end branch for the
purpose 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 sliding
friction transmitted to structural members of the building are minimized. Pipe anchoring
may be done by welding the web of a structural tee section to a reinforced section of the
pipe and the flanges of the "T" to the supporting structure or other method approved by
the Buyer.

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

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


17 PAINTING

In plant carbon steel pipes only shall be painted and identified in accordance with Table
1A.

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

All identification shall de in Spanish.

18 LIST OF ATTACHMENTS

Pressure Test Record Form
Table 1A - Legend of Labels and Color Coding
Table 2 - Size of Legend Letters
Oxygen Service Cleaning and Inspection Checklist

3
3
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 28 of 34

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 Test
Starting Starting
Time: Time:
Pressure: Pressure:
Temperature: Temperature:
Finish Finish
Time: Time:
Pressure: Pressure:
Temperature: Temperature:
Leak Rate: Leak Rate:
Comments:


Tested by: (Print name, sign & date.)


Startup Engineer: (Print name, sign & date.)

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 29 of 34

TABLE 1A: LABELS AND COLOR CODING LEGEND
Pipe
Natl
CODIGO
DE
SERVICIO
DESCRIPCION LEGENDS FOR LABELS
COLOR DE
TUBERIA
CUBIERTA
DE CAMPO
LETRAS

SERVICE
CODE
DESCRIPTION
PIPE PAINT
COLOUR
FIELD COVER
COLOR
LETTERING
COLOR
Spanish Spanish Spanish Spanish
English English English English
WATER, ABOVE GROUND AGUA, SOBRE TIERRA
SUMINISTRO DE AGUA DE
ENFRIAMIENTO VERDE VERDE BLANCO CS CWS
COOLING WATER
SUPPLY
COOLING WATER SUPPLY GREEN GREEN WHITE
RECUPERACION DE AGUA DE
ENFRIAMENTO
VERDE VERDE BLANCO
CS CWR
COOLING WATER
RETURN
COOLING WATER RETURN GREEN GREEN WHITE
AGUA PARA USO D0MESTICO VERDE VERDE BLANCO
CS DW DOMESTIC WATER
DOMESTIC WATER GREEN GREEN WHITE
AGUA DE INCENDIO ROJO ROJO BLANCO
CS FPW
FIRE PROTECTION
WATER
FIRE PROTECTION WATER RED RED WHITE
AGUA FRESCA VERDE VERDE BLANCO
CS FRW FRESH WATER
FRESH WATER GREEN GREEN WHITE
AGUA DE SELLO GREEN GREEN WHITE
CS GSW GLAND SEAL WATER
GLAND SEAL WATER VERDE VERDE BLANCO
AGUA DE PROCESO GREEN GREEN WHITE
CS PRW MILL WATER
MILL WATER VERDE VERDE BLANCO
AGUA POTABLE GREEN GREEN WHITE
CS PW POTABLE WATER
POTABLE WATER VERDE VERDE BLANCO
AGUA CRUDA VERDE VERDE BLANCO
CS RW RAW WATER
RAW WATER GREEN GREEN WHITE
AGUA DE OSMOSIS REVERSA VERDE VERDE BLANCO
CS RO REVERSE OSMOSIS
REVERSE OSMOSIS GREEN GREEN WHITE
CS LPS STEAM VAPOR NONE AMARILLO NEGRO
STEAM
NONE
YELLOW BLACK
3
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 30 of 34
TABLE 1A: LABELS AND COLOR CODING LEGEND
Pipe
Natl
CODIGO
DE
SERVICIO
DESCRIPCION LEGENDS FOR LABELS
COLOR DE
TUBERIA
CUBIERTA
DE CAMPO
LETRAS

SERVICE
CODE
DESCRIPTION
PIPE PAINT
COLOUR
FIELD COVER
COLOR
LETTERING
COLOR
OIL & GAS, HYDROCARBONS
ACEITE COMBUSTIBLE GRIS GRIS NEGRO
CS FO FUEL OIL
FUEL OIL GREY GREY BLACK
GASOLINA GRIS GRIS NEGRO
CS GAS GASOLINE
GASOLINE GREY GREY BLACK
GRASA GRIS GRIS NEGRO
CS GR GREASE
GREASE GREY GREY BLACK
ACEITE HIDRAULICO, HP GRIS NEGRO
SS HOH HYDRAULIC OIL, HP
HYDRAULIC OIL, HP
NO
GREY BLACK
ACEITE HIDRAULICO, LP GRIS NEGRO
SS HOL HYDRAULIC OIL, LP
HYDRAULIC OIL, LP
NO
GREY BLACK
ACEITE DE LUBRICACIN, HP GRIS NEGRO
SS LOH LUBE OIL, HP
LUBE OIL, HP
NO
GREY BLACK
ACEITE DE LUBRICACIN, LP GRIS NEGRO
SS LOL LUBE OIL, LP
LUBE OIL, LP
NO
GREY BLACK
GAS NATURAL GRIS GRIS NEGRO
CS NG NATURAL GAS
NATURAL GAS GREY GREY BLACK
GAS PROPANO GRIS GRIS NEGRO
CS PG PROPANE GAS
PROPANE GAS GREY GREY BLACK
CARGA ORGANICO NO GRIS NEGRO
SS LO LOADED ORGANIC
LOADED ORGANIC NO GREY BLACK
ESTERILES ORGANICOS NO GRIS NEGRO
SS BO BARREN ORGANIC
BARREN ORGANIC NO GREY BLACK
REAGENTS
ALUM AMARILLO NEGRO
HDPE AL ALUM
ALUM
NO
YELLOW NEGRO
ANTIINCRUSTANTE AMARILLO NEGRO
HDPE AS ANTISCALENT
ANTISCALENT
NO
YELLOW NEGRO
FLOCULANTE AMARILLO NEGRO
HDPE FL FLOCCULANT

NO
YELLOW NEGRO
ESPUMANTE AMARILLO NEGRO
POLY MB FROTHER
FROTHER
NO
YELLOW NEGRO
3
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 31 of 34
TABLE 1A: LABELS AND COLOR CODING LEGEND
Pipe
Natl
CODIGO
DE
SERVICIO
DESCRIPCION LEGENDS FOR LABELS
COLOR DE
TUBERIA
CUBIERTA
DE CAMPO
LETRAS

SERVICE
CODE
DESCRIPTION
PIPE PAINT
COLOUR
FIELD COVER
COLOR
LETTERING
COLOR
LECHADA DE CAL AMARILLO NEGRO
HDPE ML MILK OF LIME
MILK OF LIME
NO
YELLOW NEGRO
HIDROSULFURO DE SODIO AMARILLO NEGRO
HDPE NA
SOLDIUM
HYDROSULFIDE
SOLDIUM HYDROSULFIDE
NO
YELLOW NEGRO
HIDROSULFURO DE SODIO GRIS AMARILLO NEGRO
CS NA
SOLDIUM
HYDROSULFIDE
SOLDIUM HYDROSULFIDE GREY YELLOW NEGRO
XANTATO AMILICO DE
POTASIO AMARILLO NEGRO HDPE PAX
POTASSIUM AMY
XANTHATE
POTASSIUM AMY XANTHATE
NO
YELLOW NEGRO
AEROFLOAT 238 AMARILLO NEGRO
HDPE RAF AREOFLOAT 238
AREOFLOAT 238
NO
YELLOW NEGRO
SILICATO DE SODIO AMARILLO NEGRO
HDPE RSS SODIUM SILICATE
SODIUM SILICATE
NO
YELLOW NEGRO
ACIDO SULFURICO AMARILLO NEGRO
SS SAC SULFURIC ACID
SULFURIC ACID
NO
YELLOW NEGRO
SODA CAUSTICA AMARILLO AMARILLO NEGRO
CS SH CAUSTIC SODA
CAUSTIC SODA YELLOW YELLOW NEGRO
AMONIACO ANHIDRIDO AMARILLO NEGRO
SS AHA
ANHYDROUS
AMMONIA
ANHYDROUS AMMONIA
NO
YELLOW NEGRO
ACUOSA DE AMONIACO AMARILLO NEGRO
SS AQA AQUEOUS AMMONIA
AQUEOUS AMMONIA
NO
YELLOW NEGRO

COMPRESSED AIR SYSTEMS


AIRE DE SOPLADOR AZUL AZUL BLANCO
CS BA BLOWER AIR
BLOWER AIR BLUE BLUE WHITE
AIRE DE INSTRUMENTACION AZUL AZUL BLANCO
CS IA INSTRUMENT AIR
INSTRUMENT AIR BLUE BLUE WHITE
AIRE DE PLANTA AZUL AZUL BLANCO
CS PA PLANT AIR
PLANT AIR BLUE BLUE WHITE
OXIGENO AZUL BLANCO
SS GOXH OXYGEN
OXYGEN
NO
BLUE WHITE

3
Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 32 of 34
Table 1 Notes:

1. For all insulating tubes and pipes unpainted, such as stainless steel and
plastic pipes, colored labels are used for identification of the contents of the
pipe. "Color field" refers to the color of the basis of these labels. The colors
shall 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 and
ships).


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.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-
009_3.doc

Page 33 of 34

TABLE 2 - SIZE OF LEGEND LETTERS
Outside Diameter
of Pipe or Covering, Note 2
mm
Minimum Length of
Color Field, Note 1
mm
Size 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 the
pipe.

Project No. C-560
General Specification 000-GC-P-009
Piping Installation
Rev. 3

Q:\Shared\R0534200\01_Eng_Doc\05_Pip\01_Design_Criteria\02_Int_App\000-GC-P-009 Piping Installation\560-000-GC-P-009_3.doc

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 Location
Date 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 Used
Method(s)
Inspection
White Light UV Light
Odor Test Wipe
Test
White Light UV Light
Odor Test Wipe Test
White Light UV Light
Odor Test Wipe
Test
White Light UV Light
Odor Test Wipe Test
Inspection Result Pass Fail Pass Fail Pass Fail Pass Fail
Inspector Printed Name: Signature: