2352 0000 50DC 001 - 0

Minera Yanacocha SRL Gold Mill Project Cajamarca Peru Contract 53235200
Project Specification 2352-0000-50DC-001 20 Dic 2005 Page 1 of 46 Rev 0
PIPING DESIGN CRITERIA
This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions.
Rev. No. A A1 B 0
Date
Originator's Name & Initials
Reviewed /Checked By Name & Initials Jaime Asenjo / JAN Jaime Asenjo / JAN Jaime Asenjo / JAN Jaime Asenjo / JAN
Description / Issue
21 Oct 05 Rodrigo Barra / RB 16 Nov 05 Rodrigo Barra / RB 30 Nov 05 Rodrigo Barra / RB 20 Dic 05 Rodrigo Barra / RB
Issued for Internal Review Re-issued for Internal Review Issued for Client Approval Approved for Design
APPROVALS Lead Engineer: Project Manager: Engineering Manager: Client Representative: Jaime Asenjo F. M. Caichac Freddie Colon Kim Hackney
SIGNATURES
DATE
ISSUED FOR :
Design
Construction
Other
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Piping Design Criteria

Table of Contents Section 1.0 2.0 3.0 4.0 GENERAL......................................................................................................................... 3 PRODUCTS ...................................................................................................................... 6 SIZING GUIDELINES ..................................................................................................... 32 ATTACHMENTS ............................................................................................................. 46
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1.0 GENERAL 1.1 A. Summary Scope The Piping Design Criteria establishes the engineering standards and practices to be followed in the execution of design of the Yanacocha Gold Mill Project (YGM) for Minera Yanacocha S.R.L., Per. Considers the sizing of piping systems and mechanical items associated with slurry, water, and compressed air, process solution, pipe routing, drawing practices and piping documentation. This Criteria considers the design of piping systems such as: 1. 2. 3. 4. 5. 6. 7. 8. 9. Launders or pipelines operating under gravity (free surface flow) Pipelines operating under pressure Pumping tanks and transfer boxes Slurry pumps Water pumps Process Solution pumps Compressed air systems Heat exchanger systems Vendor Packaged systems
This criteria considers the characteristic of fluids such as: 1. 2. 3. 4. 5. 6. 7. 8. 9. Water Process Solutions Slurries (ore, lime, etc.) Plant air Instrumentation air Reagents Sulfuric Acid Sewage Diesel Fuel
10. Lube oil
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This Criteria considers the following engineering deliverables: 1. 2. 3. 4. 5. 6. 7. 8. 9. Piping & Instrumentation Diagrams (P&ID) Piping drawings Pump systems calculations Gravity systems calculations (launders, gravity lines) Piping Materials Specification Technical Specification Line list Tie-in list Supports List
10. Isometric B. Related Specifications 1.2 000.250.50003 2352-0000-45DC-001 2352-0000-70DC-001 2352-0000-55TS-001 Piping Materials Specification. Fire Protection Design Criteria. Instrumentation & Control System Design Criteria General Site Conditions
Codes and Standards The following referenced publications form part of this specification. Each publication is the latest revision and addendum in effect at the time of the project's execution unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, all Work included herein shall conform to the applicable provisions of the following referenced publications: ASME / ANSI (American Society of Mechanical Engineers / American National Standards Institute) Code for Pressure Piping, B31.3: Process Piping.
Design covered by codes other than ASME/ANSI B31.3 shall be indicated on the piping and instrumentation diagrams (P&IDs). This specification may be used
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with other sections of the ASME/ANSI B31 Code and Section 1 of the ASME Code, where applicable. ANSI ASME API MSS ASTM AWS AWWA HIS MSHA NFPA OSHA PFI PPI RNC Newmont American National Standards Institute American Society of Mechanical Engineers American Petroleum Institute Manufacturers Standardization Society of the Valve and Fittings Industry American Society for Testing and Materials American Welding Society American Water Works Association Hydraulic Institute Standard Mining Safety and Health Administration National Fire Protection Association Occupational Safety and Health Administration Pipe Fabrication Institute Plastic Pipe Institute Reglamento Nacional de Construcciones Sistema de Gestin 5 Estrellas, Estndares Medioambientales 2004, NEM-ENV-S.000-A.01, Versin 2.0
1.3
Measurement units The dimension units shall be the International Unit System (SI), except for nominal diameters of piping and fittings which shall be shown in inches. Power motors for pumps and compressors shall be shown in kilowatts (kW).
1.4
Drawing and Documents Numbering, format, layout of drawing and document shall be in accordance with the Project Procedure Manual.
1.5
Piping And Instrumentation Diagrams Piping and instrumentation diagrams shall be developed based on process flow diagrams (PFD).
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All equipment, instrumentation, controls, and interlocking participating in process operations shall be shown on the piping and instrumentation diagrams. Except for vendor packaged supplied equipment where only safety shutdowns and interlocks shall apply. See Instrumentation & Control System Design Criteria, N 2352-0000-70DC-001. Slurry pipeline slopes, as well as other special considerations, shall be indicated if possible along with the pipeline number. Reference to an explanatory note shall be made only when required. Piping identification shall be as per Piping Materials Specification, N 000.250.50003. 1.6 Quality Assurance Project piping engineers and piping design supervisors monitor, review, and control the design activities of personnel assigned to the project to ensure that applicable codes, practices, and specifications are being followed to meet project quality goals, according to discipline quality plans & work instructions. 1.7 Piping System Design All plant pipelines and valves diameter above 1/2 inclusive of shall be modeled in 3D with PDS, with exception of vendor package lines and yard piping from/to La Quinua, Yanacocha Norte or other Yanacocha plants outside the Yanacocha Gold Mill plant. All in and on line shall be represented and tagged in PDS model. Flow direction shall be shown on all lines. 2.0 PRODUCTS 2.1 A. B. C. Materials Piping materials shall be in accordance with Piping Materials Specification, N 000.250.50003. No copper, aluminum, brass or bronze alloys will be used where there is any possibility of the presence of cyanide or cyanide solutions. All buried yard piping for the water systems: fresh water, treated waters and firewater shall be preferably designed with HDPE pipe.
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D. Metallic piping shall be used for all pump suction and discharge manifolds. HDPE shall be used for process solutions, where no limitations of temperature, pressure, supports or safety considerations preclude its use. CPVC and PVC pipe and fittings used for outdoor service shall be painted with a heavily pigmented, exterior water-based latex paint. Install flat face flanges only against flat face cast iron valves and equipment. Locking devices for valves shall be provided by the client, except where noted otherwise. Minimum pipe size shall be , except for connections to equipment. Do not use pipe sizes 1-1/4, 2-1/2, 3-1/2, and 5 except for connections to equipment or fire protection piping. General Design Requirements All equipment and componets shall be designed in accordance with the General Site Conditions N2352-0000-55TS-001. Base relation of units, location of equipment, and routing of pipe on economics, safety, easy of maintenance, operation, and construction requirements. The alignment of equipment and routing of pipe shall offer an organized appearance. Piping shall be arranged in an orderly manner and routed as directly as practical, preferably in established banks or pipe ways. All isometric for 2 or smaller piping is referential and shall be field checked before construction. Process solution lines shall be preferable above ground. Solution pipelines that run in lined open trenches shall rest on HDPE sandbag sleepers into the solution channels so that liners are prevented from damage. Trenches will be designed such that they will self drain to any process pond or lined process channel. When pipe above ground is not possible (as in the cases of road crossings, obstacles, etc.) double containment criterion shall be applied by means of a secondary pipe. This secondary containment shall be designed to resist any load related to the ground. No process piping shall run beneath the concrete floors of any of the process facilities unless approved by Client. Solution piping in pipe ways and long runs shall not be smaller than 2. Major lines normally shall be carried on overhead pipeways. In certain instances, they may be buried, providing they are adequately protected. Lines that must be
E. F. G. H. 2.2 A. B.
C.
D.
E. F. G.
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run below grade, and must be periodically inspected or replaced, shall be identified on the P&IDs; place these lines in covered concrete trenches or inside pipe containment. Cooling water may be run above or below ground, based on economics criteria. Domestic or potable water shall be run preferably underground. Pipe support spacings shall be maximized using the limits of pipe spans and structural integrity. H. I. Avoid dead ends, especially for piping where solids or fluids may crystallizing or form corrosive condensate. In these cases the P&IDs shall include drain ports. The location and spacing of offsite storage tanks and dike requirements shall be in accordance with Peruvian regulation (RNC / DGH, Divisin General de Hidrocarburos), NFPA, and OSHA, where applicable. Spacing may be increased for construction requirements. Layout equipment, pumps, and exchangers to permit economical pipe routing. Locate this equipment outside of limit storage areas, except where indicated otherwise on the P&IDs. The plant layout of equipment shall utilize common structures for equipment, vessels, and pumps. Spacing and routing of piping shall be such that expanding/contracting lines (including insulation) will not clash with adjacent lines, structures and instrument and electrical equipment during warm up and cool down. Precautions shall be taken when designing lines carrying acids, cyanide and other hazardous fluids to minimize the risk of spraying in the event of a leakage. Flange joints shall be minimized and shrouds fitted to contain the spraying. These lines shall be located in the bottom level of piperacks to minimize the risk of leakage onto other piping, and cable trays. In air systems, branch lines shall be taken from the top of the mains and the feeder lines shall be taken from the top of the branch lines. The mains and branches shall be sloped toward low points as possible. Inaccessible low points shall be drained with automatic moisture traps. In water systems branch lines shall be taken from top or lateral of mains and feeders lines likewise, taking branch lines from the bottom of mains and taking feeder lines from the bottom of the branch lines shall be avoided. Transient analysis shall be developed when water hammer is likely to occur. The installation of special accessories in the piping (relief valves, delay check valves, surge anticipation valves, etc.) shall be considered to reduce its effect.
J.
K. L.
M.
N.
O.
P.
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2.3 A. Specific Design Requirements Slurry Pipe System 1. Slurry conveying pipelines shall be designed with minimum changes in direction in order to reduce abrasion and possibilities of obstruction. When possible, slurry shall be transported in a straight line from one equipment item to another. Valve use should be avoided in this application and, to the extent posible, suitable slopes for emptying of lines when they are out of service should be considered. Whenever possible, mitered elbows shall be avoided, only bends shall be used. Minimum bend radius shall be, if possible, 5 times the pipeline diameter. Bends shall generally have a rubber lining. Victaulic type, 77 style up to 24 diameters and 44 style for diameters greater than or equal to 26 couplings shall be used, and piping supports shall be preliminarily defined in order to verify that they may be easily dismounted. Pipe flushing connections and drain points shall be indicated in the Piping and Instrumentation Diagrams, all pump suction lines requiring them, as well as in all those points of the system where a possibility of obstruction may exist. Pump suction lines shall be as short as possible and bends should be avoided, as well as valves at the pump suction end. In order to facilitate maintenance, a Victaulic-type quick-coupling joint shall be provided at pump suction and discharge. Where a stand-by pump is used, the pipelines connecting it with the pump in operation shall be designed so as to avoid obstruction of the line of the pump which is not operating. Connections for flushing pipeline and draining shall also be provided. When required, vents shall be installed in pipeline high points and drainages in low points. Minimum pipe line diameter and slope shall be calculated for each pipe line slurry, according to process information.
2.
3.
4.
5. 6. 7.
8. 9.
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B. Water Supply System 1. In water supply systems, precautions shall be taken in regard to those pipelines susceptible to experiencing freezing and that may not be drained. Line drainages shall be located in dead end sections and in low points. Equipment shall be installed in such a way that pipes may drain by gravity and remain free from water. The high points of each main line shall have manual vent to eliminate trapped air. Automatic purge air valves shall be used in areas distant from operating sites. Filters shall be installed temporarily in pump suction lines.
2. 3. 4. C.
Plant Air 1. Air pipelines shall be provided with adequate drainages. Valves and water collectors with drainages at the bottom points of the air pipes shall be installed. Branch outlets shall be from the top of the main pipe. The service air system shall be sized so as to provide an adequate air supply for equipment operating condition.
2. D.
Instrumentation Air 1. 2. The service air system shall be sized so as to provide an adequate instrumentation air supply for equipment operating condition. Instrumentation air distribution pipes shall be designed as indicated in the Piping and Instrumentation Diagrams and in the respective specifications. Details of instrument connections shall be in accordance with Instrumentation & Control System Design Criteria, N 2352-0000-70DC001.
E.
Fittings and Branch Connections 1. 2. All branch connections shall be in accordance with the Piping Materials Specification N 000.250.50003. All welded elbows shall be long-radius-type bends. Other types shall be considered as special requirements and, if used, shall be identified in drawings. When allowed by the Piping Materials Specification, Miter
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type bends and welded bends should be used in 14 diameter, and over 14 diameter pipelines. 3. 4. In all cases bent pipelines (curved) shall be considered. Minimum bend radius shall be 5 times the diameter of the pipeline. The size, classification and face type of all connections flanged to pumps, tanks, or other flanged equipment, shall be indicated in general drawings, since they are special and different from the line specification. Flanges to be used shall be in accordance with the ANSI standard and flange class shall be selected depending on the required duty, unless otherwise indicated in the Piping Materials Specification, N 000.250.50003, or when connection with a special flange is necessary. Slip-on type flanges and lap-joints are preferred for welded end fittings in Schedule 5, 5S, 10 or 10S pipelines. Socketweld fitting classification shall be in accordance with pipeline class. Forged nipples or welding reductions shall be used for pipeline diameter changes. Reduction tees should be avoided. Steel flanges connected to cast iron equipment with flat face flanges shall also be flat face flanges and gasket for this application shall be used.
5.
6. 7. 8. 9. F. Valves 1.
The type of valve to be used shall be that indicated in the Piping and Instrumentation Diagrams and in the Piping Materials Specification, N 000.250.50003. As possible no valves shall be installed with the valve stem in the horizontal. Whenever shut-off valves are used in main service pipelines, these shall be installed in horizontal sections and in high points, so that the line may drain in both directions from the valve. Large, heavy duty valves shall preferably be provided with pneumatic or hydraulic driving, with local and/or remote control. For continuous and steady flows, swing check valves may be installed in horizontal and vertical position. For pulsating flows, plug or ball check valves shall be used. Where there is a possibility of water hammer, each
2. 3.
4. 5.
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case shall be analyzed separately and indications shall be included in the design drawings. 6. Valves shall be avoided in slurry conveying. Should it be strictly indispensable, valves to be selected shall be used in open/closed services, but not for regulation purposes. Valves located in pipelines which service is considered hazardous, shall be supplied with locks. Manual Valve Use Below is a list of the most frequent applications of the different types of valves. However, as a general guide and for special cases - such as high load loss or very abrasive conditions - additional considerations shall be contemplated. Valve use shall be in accordance with Piping Materials Specification, N 000.250.50003. a. Gate Valve As shut-off valve in non-abrasive services b. Cone Valve As shut-off valve in slurry pipelines. c. Globe Valve Used as flow regulating valve in non-abrasive services. d. Butterfly Valve This can be used as shuft-off valve in 3 and over 3 diameter water pipelines, since that there is a gate valve in place as the main shut-off valve at the connection from the main. It is also used as regulating valve under corrosive conditions and as drainage valve when no full port is required, specifying the linings suitable for the service. It should not be used in slurry pipelines. The use of this valve in its wafer type should consider pipeline disassembly requirements. e. Diaphragm Valves Used as cut-off valve and regulating valve (weir type) in abrasive slurries and scale-forming liquids.
7. 8. 9.
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f. Pinch Valves Used as flow regulating valve in abrasive slurries at low pressure. g. Knife Valves As shut-off valve in slurry pipeline, only for low pressure flows. h. Ball Valve As cut-off valve in 2 and less than 2 diameter water and air pipelines, or as a quick shut-off valve in services requiring it (reagents, fuels, oil, etc.). This type of valve is suitable for some slurry applications, in on-off operation with metal-metal seal. G. Control Valves 1. 2. All control valves shall be appropriately located and shall be accessible from the ground or platforms. Sufficient clearance shall be left between the bottom point of a control valve and the floor, platform or ground, to allow for the disassembly of the valve plug and stem. A drainage with valve shall be installed upstream of control valves and in the low point downstream of cut-off manual valves. Control valves shall preferably be installed in horizontal position, with the stem and control items in vertical position over the horizontal. Control valves should have a by-pass with manual regulation valve to maintain the operational flow during valve maintenance if a line stoppage would significantly affect production. Control valves shall be specified jointly for Instrumentation and Process Disciplines.
3. 4. 5.
6. H. Pumps 1. 2.
Locate pumps close to the equipment from which they take suction. Normally, locate pumps immediately adjacent to pipe racks. Design piping to provide clearance for pump or driver removal. Similarly, on end suction pumps, piping shall permit removing suction cover and pump impeller while the suction and discharge valves are in place.
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3. Arrange suction lines to minimize offsets. The suction lines shall be short and as direct as possible, and shall step down from the equipment to the pump. Eccentric reducers shall be installed in pump suctions as follows: a. b. 5. Flat on top (FOT) for aqueous solutions. Flat on bottom (FOB) for slurries.
4.
Orientate valve handwheels or handles so they will not interfere with pump maintenance or motor removal. Valve handwheels or handles shall be readily operable from grade. Provisions shall be made for forklift, mobile crane or carry deck crane access to small horizontal pumps. Overhead hoists or cranes shall be used to service large horizontal pumps and vertical pumps that are not accessible to external mobile equipment. Piping shall be routed for best service and access to pumps. Should this become difficult because of the area layout, removable pipe spools shall be included to provide access. Pumps located next to large tanks shall have sufficient pipe flexibility to allow for thermal expansion and settlement of the tanks by means of expansion joints located on the pump suction. Application of flexible devices at the pump discharge side will be analyzed for every particular case. Provisions shall be made for start-up strainers where applicable. For all centrifugal pumps, a check valve shall be installed in the discharge line between the pump and the shutoff valve, unless specified otherwise. Suitable supports and anchors shall be provided for piping to pumps so that excessive pipe reactions will not be transmitted to the pump nozzles or casings. Where piping has to be supported from grade, adjustable pipe supports shall be provided. Removable maintenance spools shall be free of supports, but all other piping shall be designed to have undisturbed support during pump maintenance. All split-casing, horizontal, centrifugal pumps shall be equipped with vents in the upper part of the volute. If shell or feed line design prevents the formation of air pockets, then such vents shall not be specified. For pumps, during plant start-up filters shall be temporarily installed at pump suction, and shall be removed upon commencement of normal
6.
7.
8. 9.
10.
11.
12.
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operation. These filters shall be identified in the Piping and Instrumentation Diagrams and shall be installed in the first flange joint between the pump and the cut-off valve in the suction line side. Y type filters shall be installed on a permanent basis where pipe coupling is threaded or socket welded. When calculating the sizes of the flange to flange pieces (spools), filter length and the additional packing should not be considered. 13. All pumps installed in zones or services exposed to freezing or embankment shall be provided with a valve drain, at suction and discharge. A short section of piping, with Victaulic joint, shall be installed at slurry pump suction and discharge to facilitating maintenance. Heavy-duty slurry pumps with serious settling risk shall preferably be assembled with the horizontal discharge on the lower level to allow for total drainage. Additionally, they shall be provided with water injection at the suction end.
14. 15.
I.
Storage Tanks 1. 2. Tank isolation valves shall be positioned on the tank nozzles. Adequate flexibility shall be provided in connecting piping such that the tank nozzles and valves will not become overstressed when tank settlement occurs. Open overflow lines shall not be installed on tanks containing flammable liquids. Piping through concrete walls shall be installed through pipe sleeves. Feed lines from the tanks to the pumps shall be arranged such that the lines are not at an elevation higher than the tank nozzle. Tanks containing cyanide, cyanide solutions, acid water or other dangerous or contaminant substance shall be installed on a contained area. Pipes shall be self-drained to the storage tanks when possible.
3. 4. 5. 6.
J.
Reciprocating Compressors 1. Specify compressors as packaged equipment.
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2. Suction and discharge lines that are subject to vibration (mechanical and acoustical) normally shall be routed at grade and held down at points established by analysis of the system. Accessibility and maintenance for large lifts such as cylinder, motor rotor, and piston removal shall be by mobile equipment. Horizontal, straight line, reciprocating compressors shall have access to cylinder valves. Access shall be from grade or platform if required. Depending on unit size and installation height, horizontal-opposed and gas engine driven reciprocating compressors may require full platforming at the operating level. The sizing, routing, supporting, and restraining of the suction and discharge piping is subject to review by means of an analog computer study.
3. 4. 5.
6.
K.
Centrifugal Compressors 1. 2. Specify compressors as packaged equipment. Top suction and discharge lines either shall be routed to provide clearance for overhead maintenance requirements, or shall be made up with removable spool pieces. Locate lube and seal oil consoles adjacent to and as close as possible to the compressor. Oil return lines from the compressor and driver shall have a minimum slope of 50 mm per meter to the inlet connection of seal traps, degassing tanks, and oil reservoir. Review the equipment arrangement for access and operation. Pipe the reservoir, compressor bearing, and seal oil vents to a safe location at least 1.8 m above operator head level. Heavy parts such as upper or inner casing and rotor shall be accessible to mobile equipment. Support piping so as to minimize dead load on compressor nozzles; the load shall be within the recommended allowance of API-617. Centrifugal compressors shall have full platforming at operating level. Centrifugal compressors shall be installed at ground level.
3.
4. 5. 6. 7. 8.
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L. In-Line Instruments 1. Control valves shall be accessible from the operating level or operating platforms. All efforts shall be made to ensure that they are located in sight of instruments or indicators showing the variables they control. Control valves shall be provided with block valves and hand-operated valve bypasses, unless specified otherwise. Where butterfly block valves are used in conjunction with butterfly modulating valves, the block valves shall be installed at a 90 orientation with respect to the control valve. Exceptions to this shall be allowed where it is not practical due to large pipe sizes or space limitations. Magnetic flow meters and density elements shall be installed in vertical pipe runs with upward flow or in horizontal runs that rise after the flow element or in the horizontal run using eccentric reducers (flat on bottom) to ensure a full pipe at the meter. Straight runs of 8 pipe diameters upstream and 5 pipe diameters downstream shall be allowed unless otherwise recommended by the manufacturer. Orifice flow meters shall be installed in horizontal pipe runs and shall have a minimum straight run of 20 pipe diameters upstream and 5 pipe diameters downstream. Deviations from this requirement shall be subject to the manufacturer's recommendations. Orifice flanges with a centerline elevations over 4.5 m above the high point of the operating surface, except for those located in pipe ways, shall be provided with a permanent access platform or ladder. Orifice taps shall be located as follows: a. b. c. 5. Air and Gas: At the top vertical centerline, which is preferred, to 45 from the top vertical centerline. Liquid: At the horizontal centerline, which is preferred, to 45 above the horizontal centerline. The piping isometrics details shall show the required tap orientations.
2.
3.
4.
Locate liquid level controllers and level glasses so as to be accessible from grade, platform, or permanent ladder. The level glass shall be readable from grade wherever practical.
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6. Relief Valve a. It shall be ensured that the orientation of the relief valve is a such a way that the relieved liquid falls into the system spillage containment area or returns to the process system. Relief valves shall be accessible. Wherever feasible, locate them at platforms that are designed for other purposes. Relief valves with a centerline elevation over 3 m above high point of finish surface (except in pipeways) shall be accessible from platform or permanent ladder. Install relief valves, 1 and smaller, in a horizontal position when it is impractical to install in the vertical position. Install relief valves, 1 and larger, in a vertical position. Normally, install relief valves that discharge to a closed system higher than the collection header. There shall be no pockets in the discharge line. Relief valves that discharge to the atmosphere shall have tail pipes extended to a minimum of 2.5 m above the nearest operating platform that is within a radius of 8 m.
b.
c.
d.
e.
7.
Indicate control, block, and bypass valve sizes on the P&IDs. Control valves shall be accessible from grade or platforms. In general, the instruments or indicators showing the process variables shall be visible from the control valve.
M.
Temperature and Pressure Instrument Accessibility and Visibility 1. Temperature test wells, thermocouples and temperature indicators located less than 3 m above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by a portable ladder. Those located over 3 m above high point of finished surface shall be accessible from a platform or permanent ladder. Temperature indicators shall be visible from grade, ladder, or platform. Local pressure indicators shall be visible from grade, permanent ladder, or platform. Those located less than 3 m above high point of finished surface shall be accessible from grade or a portable ladder. Those located in a pipeway shall be considered accessible by portable ladder. Those over 3 m above high point of finished surface shall be accessible
2.
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from a platform or permanent ladder. For all installations, pressure gauges must have a cut off valve and a drain port with a ball valve in order to verify if the instrument is working properly and for maintenance. N. Thermal Expansion 1. Allowance for thermal expansion shall be made by the use of expansion loops or offsets, where applicable. Expansion provisions shall conform to ASME B31.3. Piping arrangement shall provide for thermal expansion of lines. Large reactions or moments at equipment connections shall be avoided, and manufacturers allowances shall be satisfied where applicable. Expansion joints shall be capable of withstanding without leakage or structural failure at least 1.5 times the working stresses imposed on them by pressure and temperature of the fluid and expansion of the pipeline. The ratings of the expansion joints shall be indicated on the Piping Materials Specification N 000.250.50003. If expansion joints are used, the piping upstream and downstream of the joint shall be guided, anchored and supported in such a manner that no misalignment of the connecting piping can occur and axial expansion and lateral movement are properly controlled. Particular care must be exercised in ensuring adequate flexibility in plastic piping systems (HDPE, CPVC, PVC, etc.) due to high thermal expansion of these materials compared to steel piping. Thermal expansion contraction evaluations shall be based on the highest and lowest ambient temperatures as well as the service conditions.
2.
3.
4.
5.
O.
Utility Stations 1. Provide utility stations with water, air and/or nitrogen as indicated below. Use a single 20 m length of hose to reach the entire working area from the station. Hose, hose rack, and hose connections shall be provided by the Client. a. b. Provide water outlets at grade level only, in pump areas, and near equipment that shall be water washed during maintenance. Provide air outlets in areas where air-driven tools are used such as at exchangers, both ends of heaters, compressor area, top platform of reactors, and on columns, so that each point to be serviced is within the reach of a 20 m hose.
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c. P. Fire Protection 1. Design, installation, testing and inspection of all fire protection systems shall be in accordance with NPFA standards and applicable local codes and regulations. For Details see Fire Protection Design Criteria N 23520000-45DC-001. Provide air and water at thickener underflow, suction pipe line.
2.4 A.
Piping Supports General 1. Piping subject to transient flow conditions shall be controlled by anchors, line stops and guides as required by flexibility analysis. The normal vibration levels transmitted from rotating and reciprocating equipments to piping should be considered as well, dead loads, live loads, seismic loads, thermal loads. Piping and pipe shoes or cradles shall sit directly on steelwork surfaces with specified supports. Generally pipe shoes are required for insulated carbon steel piping. Pipe shoes shall be provided for insulated alloy piping. Generally, pipe shoe heights shall be 100 mm. Large diameter lines 20 and above, stainless steel and alloy lines where galvanic action or excessive wear may occur at support steel, lines with wall thicknesses less than standard weight and vacuum lines shall be analyzed to determine whether pipe shoes or cradles are required at support points. All sizes of piperack piping shall be controlled against thermal expansion and contraction from ambient and process conditions. Generally, piping shall be fitted with central line stops and guides. Galvanized pipe support components shall not be used. Spring supports shall have neoprene-coated springs. Maximum allowable spacing of piping supports for piping with Victaulic type couplings shall be in accordance with the recommendation of the coupling manufacturer. The piping shall be suitably supported and anchored (particularly at elbows) to prevent leakage or separation of the Victaulic type couplings.
2. 3.
4.
5.
6. 7.
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8. Piping sections requiring frequent dismantling for maintenance, such as for the installation of spectacle blinds, shall be provided with permanent supports at each side of the section to be dismantled. Pipe support spacing shall be selected considering pipe size, service and material class. Critical lines or plastic pipes shall require special consideration related to over stressing or excessive sagging under operating conditions.
9.
B.
Hangers and Supports for Steel Piping 1. Unless supports are located on the piping drawings / isometrics, the maximum allowable spacing of metal piping supports shall be in accordance with the following schedules:
a.
Spacing Support Table for CS and SS pipe Carbon Steel Dwt Span Pipe Sch (mm) 80 2100 80 2400 80 2700 80 3300 80 3600 40 4200 40 4800 40 5700 40 6600 40 7200 Std Wt 7500 Std Wt 7800 Std Wt 8100 Std Wt 8400 Std Wt 8700 Std Wt 9000 Std Wt 9600 Stainless Steel Pipe Sch 40S 40S 40S 40S 40S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S 10S Dwt Span (mm) 2100 2400 2700 3300 3600 3900 4500 5100 5700 6300 6600 6900 7200 7500 7800 8100 8700
Pipe Size (in) 1/2 3/4 1 1 1/2 2 3 4 6 8 10 12 14 16 18 20 22 24
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Notes: b. c. d. Dwt denotes gravity (deadweight). Dwt Span gives the span required for gravity (deadweight) supports (hangers). Earthquake guide is required at every second gravity support for 3 and smaller, and at every third gravity support for 4 and larger pipe sizes. Guides for wind are required for exposed piping such as yard piping. Guides for wind loading are required at every support for pipe sizes up to 3. For 4 piping, guides for wind loading are required at every second gravity support. For 6 and larger piping, guides for wind loading are required at every third gravity support. Only wind or earthquake loading, whichever is critical, needs to be considered. Reduce all spans by 25% when there is an elbow or other welded component such as welded tee in between two supports. Provide a support closer to elbow and welded component. Provide a gravity support near concentrated mass such as valve or riser or on the riser. Accordingly, adjust the support load by including the load due to the concentrated mass or riser. This table is applicable for carbon steel and stainless steel piping, with the allowable stress equal to 103 MPa (15000 psi) or higher at the design temperature. The table applies to pipe with contents with specific gravity up to 1.3. For fluids with gravity specifies greater, should be studied specifically. Thermal expansion and concentration shall be properly accounted for when utilizing the above table.
e.
f. g.
h.
i.
j.
k. C.
Hangers and Supports for Plastic Piping 1. Unless supports are located on the piping drawings / isometrics, the maximum allowable spacing of plastic piping supports shall be in accordance with the following schedules:
2352-0000-50DC-001_R0.doc

a. Spacing Support Table for PVC and CPVC pipe PVC Dwt Span Pipe Sch (mm) 80 1370 80 1450 80 1680 80 1910 80 1980 80 2290 80 2540 80 2850 80 3150 CPVC Pipe Sch 80 80 80 80 80 80 80 80 80 Dwt Span (mm) 1370 1450 1600 1760 1980 2290 2520 2670 3000
Pipe Size (in) 1/2 3/4 1 1 1/2 2 3 4 6 8 b.
Spacing Support Table for HDPE pipe Operation Temperature 24C Pipe Size (in) 1 1 1/2 2 3 4 6 8 10 12 14 16 18 20 24 28 32 36 42 48 SDR 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 Dwt Span (mm)
700 700 900 1000 1100 1400 1600 1800 1900 2000 2100 2300 2400 2700 2900 3100 3300 3500 3700
Operation temperature 50C SDR 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 32.5 Dwt Span (mm)
500 600 700 900 1000 1200 1400 1500 1700 1700 1900 2000 2100 2300 2400 2700 2900 3100 3300
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For others SDR s use the follow multiplier factor
SDR 26 21 17 15.5 11 9 7 Notes: Factor 1.05 1.10 1.15 1.20 1.25 1.30 1.35
c. d. e.
Dwt denotes gravity (deadweight). Dwt Span gives the span required for gravity (deadweight) supports (hangers). Reduce all spans by 25 % when there is an elbow or other bonded component such as bonded tee in between two supports. Provide a support closer to elbow and bonded component. Provide a gravity support near concentrated mass such as valve or riser or on the riser. Accordingly, adjust the support load by including the load due to the concentrated mass or riser. The table applies to pipe with contents with specific gravity up to 1.0. Thermal expansion and concentration shall be properly accounted for when utilizing the above table. PVC table is based on 26.5 C and sag of 6 mm. CPVC table is based on 49 C and sag of 6 mm. HDPE Table is for sag of 2.5 mm. For specific gravity (S.G) greater 1.0 use multiplier factor (S.G.)^(-0.25) for spacing support. =
f.
g. h. i. j. k. l. 2.
Special consideration shall be given to: a. b. Lines having substantial concentrated loads such as valves and fittings, which may exceed the allowable, stress limits. Lines having local reduction in strength due to special components.
2352-0000-50DC-001_R0.doc

c. 3. Lines connecting to vessels or tanks where appreciable settlement may occur.
Pipe support spacing for plastic pipe shall be in accordance with the recommendation of the manufacturer and as noted above. Field Engineer shall make the final determination on actual support locations. Long runs of HDPE piping (contain cyanide) that are routed on the ground will be in trench. Pipe trench will be lined for environment protection draining to collection ponds. Anchoring will be provided per flexibility facilities. Long runs of HDPE piping (contain not cyanide) that are routed on the ground guided or intermittently buried to allow lateral movement of the pipe due to temperature differences during the day and right and during different seasons. Manufacturers recommendations for guide spacing should be followed. For pipes under roads or heavy traffic, minimum burial depth shall consider wall buckling, wall crushing, ring deflection and wall cracking. At road crossings, pipe shall be run through culverts.
4.
5.
6.
2.5 A.
Operability Valve Operation 1. Indicate operating valves requiring attention, observation, or adjustment during normal plant operation on the P&IDs. They shall be located so as to be within reach from grade, platform, or permanent ladder. Operating valves may be chain-operated if the bottom of handwheel is over 2.2 m above high point of finished surface or operating platform. The assessment of the need of having automatic and remote operated valves should be conducted, especially for cases where the frequency of valve operation is high. The centerline of handwheel or handles on block valves used for shutdown only, located less than 3 m above high point of finished surface, and those located in pipeways, may be accessible by portable ladder. The centerline of handwheel or handles on block valves used for shutdown only and located over 3 m above high point of finished surface, except those located in pipeways, shall be operable from permanent ladder or platform.
2.
3.
4.
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5. In general, keep valve handwheels, handles, and stems out of operating aisles. Where this is not practical, elevate the valve to 2 m clear from high point of finished surface to bottom of handwheel. Preferred height of valve handwheel from top of platform: a. b. 7. Horizontally mounted valves Vertically mounted valves 1000 - 1250 mm 1100 - 1350 mm
6.
It is preferred that check valves are located in horizontal pipe runs. If it is necessary to locate a check valve in the vertical, the suitability of the valve type shall be carefully considered. For both vertical and horizontal check valves, a drain downstream these valves shall be provided. Unless otherwise noted, open-ended valves shall be provided with a plug, screwed cap or blind flange. All lever or key operated valves shall be installed with adequate clearance for operation. Drains shall be provided up and down stream of pocketed orifice plate flow elements in all liquid services other than water. Utility piping systems (air, water and nitrogen) going into separate process units shall have a battery limit block valves with a line blind only. Individual block valves to users within the process units are not required unless specified by the Client or Process Discipline.
8. 9. 10. 11.
B.
Sample Connections 1. 2. Provide sample and test connections as indicated on P&IDs. They shall be readily accessible from grade or platform. Pressure and flow considerations shall be taken into account when designing sampling stations in such a way that samples can be taken without process interruption. In general, where liquid samples are taken in a bottle, locate the sample outlet above a drain funnel to permit free running of the liquid before sampling. Samples boxes shall enclose the sampling valve for security.
3.
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C. Vents and Drains 1. The P&IDs shall indicate the size of vents, drains, and bleeds required for plant operation, except as noted in section C3 below. Vents and drains shall be sized as follows (unless specified otherwise): a. Pipe Vent and Drainage Sizing (for not slurry) Vent Size 1 Drain Size 1
Nominal Pipe Size (NPS) to 10 12 to up
b.
Pipe Vent and Drainage Sizing (for slurry) Vent Size 2 2 2 2 2 Drain Size 2 3 4 6 8 10
Nominal Pipe size (NPS) 2 to 6 8 to 12 14 to 18 20 to 26 28 to up
c.
Tank Vent and Drainage Sizing Tank Volume (m) Up to 6 From 6 to 17 1 3 2 4 Vent Size Discharge Size (*) 2 4 3 6 3 Drain Size 2
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Tank Volume (m) From 17 to 70 From 70 to 140 From 140 to 280 From 280 to 1400 Over 1400 3 8 3 10 4 12 10 18 24 Vent Size Discharge Size (*) 4 10 4 12 6 18 12 24 36 8 6 6 6 Drain Size 4
(*): Use when there is no information on flow requirements.
2. 3. D.
For non-hazardous fluids, provide plugged hydrostatic vents and drains without valves at the high and low points of piping. Provide valved bleeds at control valve stations, level switches, level controllers, and gauge glasses per job standard.
Line Strainers 1. Provide temporary conical or plane type strainers in 2 inch and larger butt weld pump suction lines for use during startup. Arrange piping to facilitate removal. Use permanent Y-type strainers on 2 inch and smaller screwed or socket weld pump suction piping, unless otherwise specified. Provide temporary basket type strainers located at the suction pulsation device inlet for startup of reciprocating compressors. Arrange piping to facilitate removal of the strainer. Provide temporary basket type strainers and locate them as close as possible to the compressor inlet flange for startup of centrifugal compressors. Arrange piping to facilitate removal of the strainer.
2. 3.
4.
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E. Personnel Protection 1. Provide eyewash and emergency showers in areas where operating personnel are subject to hazardous sprays or spills, such as acid, or caustic. Indicate these items on the P&IDs. Provide personnel protection at uninsulated lines and for equipment operating above 60 C when they constitute a hazard to the operators during the normal operating routine. Provide leakage indicating tape and spray impingement shrouds at flanged joints in hazardous service such as acid or concentrated cyanide.
2.
3. 2.6 A.
Maintenance Clearances 1. Minimum clearances for overhead piping shall be as indicated with the following table: a. Minimum Overhead Clearances Description Over railroads Over main roadways Over secondary roadways Over accessways within project limits Within building In passage area between towers and pumps b. Minimum Spacing Clearances Description Minimum maintenance space required between flanges of exchangers or other equipment arranged in pairs Minimum clear width between adjacent vessels (including insulation) Clearance 0.6 m 1.2 m Clearance 7.05 m 6.1 m 4.3 m 3.7 m 2.5 m 2.5 m
2352-0000-50DC-001_R0.doc
Description Minimum clear width of operating and servicing areas around compressors Minimum clear width between pumps and small vessels and piping manifold Minimum maintenance space required for structural member or pipe Minimum clearance between the outside diameter of flange and the outside diameter of pipe insulation Minimum clearance between the outside diameter of pipe, flange, or insulation and structural member Minimum distance from underside of pipe to grade or platform (including insulation) Minimum clearance in front of inspection, cleanout and manway opening Clearance between the outside of valves handwheel and any obstruction Preferred centerline of control valve above grade or platform Minimum centerline of control valve out from face of column or wall
* With full consideration of thermal movements
Clearance 1.5 m 1.5 m 0.3 m *25 mm *50 mm 300 mm 900 mm 25 mm 450 mm 600 mm
B.
Piping Layout 1. Pipeline layout shall be prepared in an orderly manner and pipes shall be grouped whenever possible. Layout shall consider: easy installation, minimum interference with production, passing clearance, and facilities for maintenance purposes. Simple supporting systems shall be considered for layout definition. All pipelines shall preferably be installed above ground level, unless special conditions make it necessary to have them buried. Pipe supports shall leave a clearance of at least 300 mm between the lower edge of the pipeline and the ground, and at least 200 mm between the side edge of the pipeline and walls, to allow for suitable painting, maintenance and bolt tightening activities.
2. 3. 4.
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5. Pipelines conveying acid or other hazardous products shall be located as close as possible to the ground or floor to prevent spattering from reaching people, in case of any leakage. Flanged joints shall be located in horizontal sections; they shall be as few as possible and should be protected with suitable covers. In pipeline rack crossings, lines extending in a North-South direction shall be given different elevations from those extending from East to West; the clearance between the pipe of greater diameter and the structure pipe rack shall permit to install two 90 elbows. Preferably, pipeline elevations in racks shall be maintained; these shall be modified when requiring to avoid a siphon (due to interferences with other lines), in case of existing lines with greater diameter requiring greater spacing, or else in lines requiring slopes for drainage or gravitational conveyance. Rack-arranged pipelines shall have sufficient clearance between them as to provide access to flanges and for maintenance purposes. These distances shall be increased, as required. All pipeline layouts shall be considered underneath electric circuits and equipment installations. Pipeline spacing and layout shall contemplate clearances in such a way that pipeline expansion will not expose them to contact with adjacent lines, electric cables or structures. Sufficient clearance shall be considered for instrument installation. Inner threaded-couplings shall usually be installed at 45 or 90 from pipeline axis (center line). Piping lines having orifice plates shall preferably be installed outside pipeline racks. An adequate space shall be provided in pipeline racks for installing instrumentation lines and electric cables. This space should consider eventual pipe dripping as well as facilities for pipeline assembly, disassembly and maintenance. The final width of pipe racks shall be increased by 25% over the calculated width. All valves and control valves that will be operated frequently, as well as equipment that must be observed, adjusted or maintained on a regular basis during operation, shall be conveniently located to allow for good
6.
7.
8.
9. 10.
11.
12.
13. 14.
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access from the ground, platform or safety-railed ladders. applies to shut-off valves. 15. 16. This also
No pipelines shall be installed in areas designated for maintenance and access purposes. Whenever possible, low points in the layout of slurry pipelines and water pipelines exposed to freezing, when they are out of service, shall be avoided. Should these be unavoidable, automatic drains or heat tracers (for water) shall be provided. High point pressure shall be checked in order to prevent an eventual cavitation due to negative pressures. No pipelines or piping system shall be installed above mechanical equipment interfering with access for maintenance i.e. pumps.
17. 18.
3.0
SIZING GUIDELINES Consideration must be given to pressure drop, to maximum permissible velocity from the standpoint of erosion and noise, and to economics (when a fluid is compressed or pumped). The pipe must be sized to ensure that the total system pressure drop (including pressure drop due to control valves, equipment, etc.) does not exceed the allowable pressure drop. The following criteria shall be given as guidelines to determine pipe sizing: 3.1 A. Slurry Gravitational Free Surface Flow General Criteria This section summarizes the criteria to be used to size the slurry gravitational conveyance systems. 1. Dripping type Slurry conveyance gravitational systems shall prevent dripping from taking place at the whole pipe section, mainly the formation of traps. Surface conveyance systems should always be preferred (canals). 2. Flow Variations Conveyance system sizing shall consider a flow variation on the metallurgic balance, in the positive and negative percentages as dictated by the Process discipline.
2352-0000-50DC-001_R0.doc

The calculation flow rates shall be used according to the information presented in the proper flow sheets. B. Hydraulic Calculations 1. Sedimentation Velocity (VL) The sedimentation velocity in free-surface splashing will be calculated according to the modified Durand expression.
VL = 1,25 FL [2gh (S 1)]

Where: VL = FL = g h S C. = = =
0, 25
Sedimentation velocity [ m/s ]. Coefficient as obtained from the McElvain and Cave chart, depending on the grain size (d50) and the pulp volumetric concentration (Cv). Acceleration of Gravity [ 9.81 m/s ]. Normal splashing head [ m ]. Relative solid density
Splashing Velocity (VF) Splashing velocities shall be 10% higher than the sedimentation velocity as calculated with the modified Durand expression. Maximum flow velocity of 4m/sec will be considered to avoid an accelerated abrasion, except those specific cases where this condition cannot be reached due to an excessively high flow variation.
D.
Normal Splashing Head The normal splashing head with free surface shall be calculated using Mannings expression.
J =
Where: Q n J = = =
Q n A R 2/3
Flow, [m/s]. Mannings Roughness Coefficient Slope, [times one].
2352-0000-50DC-001_R0.doc

A R P = = = Splashing section [m]. Hydraulic ratio [m]. Wet perimeter [m].
Hydraulic ratio is defined as the quotient between the splashing section (A) and the wet perimeter (P). Mannings roughness coefficient for water splashing is a known value, whose values, depending on the conveying material, is found in extensive literature related to this subject. In the case of slurry flows, literature is not so extensive however, for splashing velocities above 10% of the sedimentation velocity, conservative values for the ranges as defined for water splashing can be adopted. According to pipeline material, the following values will be used: Material HDPE Rubber Steel Concrete Considerations The gravitational transportation systems shall take into account the following considerations: Coeff. Mannings Roughness (n) 0.011 0.012 0.012 0.013
Di h b
Di h b
= = =
Pipeline internal diameter (m) Normal splashing head (m) Launder width (m)
2352-0000-50DC-001_R0.doc
Frothy Slurries (concentrates with viscosity similar to water)
0.2
h 0.5 b
0.2
h 0.5 Di
Water and Non-frothy slurries with viscosity similar to water (ore slurry, flotation tails, floor washing)
0.3
Froude Number
h 0.6 Di
0.3
h 0.6 b
To design free-surface splashing systems, the following will be met to avoid instabilities:
Fr < 0,8
F
r
or
= V g A l
F r 1, 2
Where: Fr V g A l E. Launder Free Height The dimensioning criteria for the chute free height, that is, the freeboard between the edge of the launder and the splashing height will be the following: In a section free from singularities, leave a velocity head of 1.0 for non-frothy slurries, and a velocity head of 1.5 for frothy slurries. The free section should not be smaller than 200 mm. In sections showing singularities, leave a free section of 2(two) times the velocity head for non-frothy slurries, and 3 (times) the velocity head for frothy pulps. The free section should not be smaller than 300 mm.
2352-0000-50DC-001_R0.doc Piping Design Criteria
= = = = =
Froude Number Splashing velocity (m/s) Acceleration of Gravity (m/s) Splashing section (m) Free splashing width (m)

The calculation shall be made with respect to the maximum flow rate. Installing covers shall be considered, in order to avoid spillage, mainly in sections showing peculiarities. 3.2 Sizing of Transfer Boxes The transfer boxes shall be dimensioned so as to avoid overflow and spillage. For this purpose, the following conditions as applied to the whole range of flows defined per balance (see figure No 1) shall be complied with. The width of the transfer box shall be at least 2.5 times the width of the feed or discharge section of the box, to keep the pulp jets from striking the walls of it. This criterion shall be suitable for the velocities of the slurry inside the box. The free board of the outlet section shall be at least 1.3 times the load head (H) as required by the outlet duct, for a maximum flow. The free board (R) of the transfer box shall be, at least, 1.25 m as measured with respect to the maximum flow rate, on the pulp level (hn) as defined in the feed to transfer box section. A box depth under the base slab of the discharge section shall be considered as a slurry damping cushion (Dc). This cushion minimum depth shall be, at least, of (fall height of the pulp / 3) ^ . Slurry transfer shall be conducted so as to guarantee the hydraulic autonomy between the incoming flow and the outgoing flow of the transfer box, for which a free head between the level defined by the load head, as determined by the discharge section and the base slab of the feed section of 0.5 m, shall be considered. The length of the transfer box (Lc) shall be greater than or equal to twice the horizontal distance of the trajectory described by the drop parable (Lp) of feed slurry to the box for maximum flow. The discharge piece shall ensure that the flow shall splash in a launder accelerating towards the normal head conditions. Normal conditions, to the extent possible, shall be reached at the end of the special piece. If the outgoing duct is a pipe (D), vent tubes of a diameter 0.25 times pipe diameter (D) shall be available, located between 3 and 5 diameters from the outlet.
2352-0000-50DC-001_R0.doc

According to flow characteristics and design possibilities, transfer boxes shall be designed with: damping cushion, bottom drainages and covers to prevent froth spillage.
Lp
3D a 5D
hn H0 0.5 m
1.3 H H Dc D
Lc > 2Lp
Figure 1
3.3
Sampling Boxes The following criteria shall be considered for sampling box design: Compartments to be considered are as follows:
A.
Receiving and Deaeration Compartment. Slurry is received, deaerated, and settled in this compartment. Flowing through velocities from this compartment to the transfer compartment shall be greater than particle settling velocity.
2352-0000-50DC-001_R0.doc

B. Transfer Compartment Airless and settled slurry flows through this compartment in an ascending direction towards the discharge compartment. Should the process so require an in-line analysis test tube shall be located in this compartment. C. Discharge Compartment Slurry leaves the transfer compartment overflowing an interior weir, which will either feed a sample cutter (if the process so requires) or else fall into the discharge compartment. Slurry may be freely discharged outside of the box or with a pneumatic plug system, thus allowing a controlled flow split. 3.4 Slurry Pumping This section presents the slurry pumping system design criteria. A. Sedimentation Velocity (VL). Sedimentation velocity in pressure pipelines shall be calculated according to the modified Wasp expression:
D VL = F i WL d50
FWL = 3 , 33 C V
0 ,1977
0,333
2gD (S 1) 50
CV < 18,7%
0,3564
FWL = 3,33 CV
0,1536
(1 CV )
18,7% CV
Where : VL FWL g Di d50 S = = = = = = Sedimentation velocity [ m/s ]. A dimensional correction coefficient. Gravity acceleration [ 9.81 m/s ]. Pipe inside diameter [ mm ]. Average particle diameter [ mm ]. Solid relative density
Splashing velocities shall be 10% higher than the sedimentation velocity calculated with the modified Wasp expression. Maximum splashing velocity shall be, if possible, lower than or equal to 4 m/s.
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B. Friction Factor For pipelines the friction factor is determined by the Colebrook formula using the slurry density and viscosity to determine the Reynolds number and the proper roughness coeficient of pipe. C. Minimum Pipe Wall Thickness According to that recommended by ANSI/ASME B31.11 standard. D. Load Losses Load losses shall be calculated according to Darcys classical formula for pure fluid, considering the viscosity of the conveyed slurry. E. Roughness Coefficient The following roughness coefficients shall be considered for new piping, based on the type of material.
Material Steel HDPE Rubber
Coefficient (mm) 0.05 0.02 0.09
F.
Design Temperature (TD) Design temperature (TD) shall be the maximum operating temperature defined by process requirements.
G.
Viscosity (*) A variable viscosity based on the % of solids in weight of slurries shall be considered:
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% slurry weight < 25 25 - 45 45 - 55 55 - 70
(*): use when there is no information on flow requirements.
VISCOSITY m/s x 10-6 3 35 58 8 10
H.
NPSH (net positive suction head) For calculation consider the low oparation level for in the pumping box (or tank), this shall be calculated for the design flow.
I.
Flow variation Pumping system sizing shall consider a flow variation on the metallurgic balance, in the positive and negative percentages as dictated by the Process discipline. The calculation flow rates shall be used according to the information presented in the proper flow sheets.
J.
Pump Box Conceptual Sizing Pump box sizing shall be made so as to avoid, to the extent possible, sudden and frequent variations of positive head on the pump shaft, in addition to overflow and splatters. Fluid head with respect to the pump shaft shall be sufficient as to guarantee that the pump will work at all times with a NPSH (net positive suction head) higher than that required by the pump, in such a way that no air suction shall be produced due to vortexes or cavitation. For such purpose the following times of residence shall be considered, measured with respect to maximum design flows, considering also the greatest possible height of the box. Time of residence Non-frothy slurry Frothy copper concentrate > > 1.0 1.5 minute minutes
For Cyclone feed Pump Tank, will be lay-out considerations.
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K. Pump Selection 1. Conventional horizontal slurry pumps shall be selected with rubber or polyurethane, or similar coating for wear pieces, depending on the type of slurry to be pumped. Pump selection for non-frothy slurry shall be made so that the maximum flow rate, including the variation, does not exceed 75% of the flow range of the pump catalogue. For frothy slurry, the maximum flow rate shall not exceed 60% of the range of the pump catalogue. For slurry pumps in Grinding, the correction for the effect of solids and particle size shall be calculated with the WARMAN method. For the rest of the slurry pumps, the following safety coefficients should be applied on the total dynamic head (TDH) and on power: For the rest of the slurry pumps, the following safety coefficients should be applied on the total dynamic head (TDH) and on power: TDH Non-frothy slurries 1.1
2.
3. 4. 5. 6.
7. 8. 9. 10. 11.
Power is considered calculated with TDH correction. Motor nominal power, for a Service Factor of 1.0 shall be as a minimum the corrected calculated power, increased by 10%. Motor power shall consider a deaerating factor for transmission operation factor of 8%. For belt drive and gearbox, for the case of direct coupling, a 3% operation factor shall be considered. It shall be necessary to verify that the impellers peripheral speed does not exceed 25 m/s to prevent the accelerated wear of the impeller itself and of the shell. In any case maximum recommended speeds shall be confirmed with vendors.
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12. 13. Equipment in a pump discharge circuit should have a design pressure at least equal to the lines design pressure (PD). Pumps with variable speed engine shall be specified including the engine and frequency converter, according to electrical specifications. This system shall be quoted with a common vendor.
3.5
Milk of Lime Lines 1. 2. For sizing of milk of lime pipe use minimum flow velocity 2.2 m/s. The minimum pipe size for milk of lime line shall be 1 .
3.6 A.
Aqueous Flow Sizing Criteria Pressure Drop Criteria 1. When a given pressure or static head is available, it is relatively simple to size a line. It should be sized to consume no more than the available pressure at the rated flow conditions. The available frictional pressure loss is limited by pressure drops due to other system components (e.g., control valves, equipment, etc.).
B.
The frictional pressure drop for single-phase systems should be calculated using the Darcy-Weisbach formula. To determine the friction factor, the Colebrook equation or the Moody nomogram should be used. Roughness Coefficient is the same of slurry. 1. The following are the recommended maximum pressure drops due to friction loss: a. b. c. 2. Liquid pressure lines: 5% of line length. Liquid gravity lines: 3% of line length. Compressed air: 12 kPa per 100 m of line.
A safety margin from 5% to 20 % shall be added to all friction loss calculations to take into account the pipe aging, difference in diameter or any abnormal condition of interior pipe surface, with the exception of steam systems, for which no margin is to be added. A safety margin should only be added to frictional losses, and not to pressure losses due to elevation changes or acceleration.
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C. Velocity Criteria 1. Every calculated line size must be checked to ensure the resulting velocity is reasonable. If a line size is not governed by pressure drop availability or economics, then velocity limits are usually the deciding factor. In addition, other velocity limitations, such as settling, erosional velocity, sonic velocity, entrainment velocity and noise, must be considered when sizing lines. When the velocity is the deciding factor, the aqueous solution pipes should be sized based on the design flow rate by using the following velocity criteria: a. b. c. 3. For secondary water lines, maximun flow speed of 3.0 m/s shall be considered. For mains lines, the maximum speed shall be 2.0 m/s. Pump suction and drain lines: 1.0 to 2.0 m/s.
2.
The velocity criteria above are intended as a general guideline. Velocity outside the ranges specified above may be acceptable and should be evaluated on a case by case basis. Velocities up to 3.0 m/s are acceptable for larger pipe sizes.
D.
Thickness Pipe Calculation 1. Joukowskys ratio shall be applicable to water hammer calculation, using the elasticity modules: 2. Steel Water 2.1 x 106 kg/cm 2.07 x 104 kg/cm
For Thickness pipe calculation use ASME B31.3 code
E.
Pumping System 1. Booster Plant All continuous service booster plants shall have at least one backup (stand-by) pump and engine group, consequently continuous pumping stations shall have at least two pump and engine groups alternating the operation of these units.
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In regard to reclaimed water pumping the booster plant shall eventually operate with all pumps simultaneously, including the stand-by pump. The stand-by pump and engine group shall be equal to the rest, or to the most critical of booster plant equipment. All pump stations and valve chambers shall be provided with heaters that will prevent freezing in case of stoppage of all pumping equipment. In regard to pipelines exposed to risk of freezing, design should consider a purging system. All pumps shall consider cut-off and check valves in discharge lines, with access for manual operation in addition to their electromechanical drive. Lines shall be designed and arranged in such a way that an adequate clearance shall be provided for pump and/or motor disassembly without the need for dismantling pipe sections. The pumping stations shall permanently have material handling equipment to lift or transport any item contained in the station. Sizing of the same shall be based on manufacturers standards. 2. Pump Sizing Pump motor sizing shall be made considering the following power expression:
p=
Where: p
Q H 1000 p m
Q H
p
m
= = = = = =
Motor power (kW) Specify weight (N/m3) Water flow rate to be pumped (m/s) Total dynamic head (m) Pump efficiency (times one) Motor and transmission efficiency (times one)
2352-0000-50DC-001_R0.doc

Pumps shall be sized in such a way that the maximum flow rate, including variation, does not exceed 80% of the range of the pump catalogue. A safety coefficient of 5% shall be applied in pump total dynamic head (TDH) calculation. For motor power calculation safety coefficient will be evaluated in case by case. Minimum pipe thicknesses shall be calculated considering that at the end of their useful life they will withstand: Design pressure without exceeding 50% of the flow effort. Eventual pressure (water hammer) without exceeding 75% of flow effort. Additionally, design thickness should consider the following: 2 mm overthickness for corrosion effects: 3.7 Compressed Air Flows The design of compressed air networks shall consider a tolerance in the capacity for transporting air in mains, in order not to cause significant pressure drops in case of high air consumptions. The tolerance to be considered in the capacity of the line with regard to normal requirements shall be 20%. For safety reasons, water traps should be considered in bottom points, with automatic or manual drainage. Determination of pressure drops in a compressed air line. calculation expression is as follows: The general
P = P1 P2 =
Where: P = L = D = V = M = = g =
L V2 M D 2 g
Pressure drop (Pa) Pipe length (m) Pipe inside diameter (m) Average air speed (m/s) Average specific weight of the air circulating in the pipeline (N/m). Tube friction coefficient (a dimensional) Gravity acceleration (m/s2)
2352-0000-50DC-001_R0.doc

4.0 ATTACHMENTS N/A. End of Specification
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Minera Yanacocha SRL Gold Mill Project Cajamarca Peru Contract 53235200

Project Specification 2352-0000-50DC-001 20 Dic 2005 Page 1 of 46 Rev 0

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Originator's Name & Initials

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10. Lube oil

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Reciprocating Compressors 1. Specify compressors as packaged equipment.

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