Aker Kvaerner

PROJECT N° C-454

COMPAÑIA MINERA RIOCHILEX S.A.

SPENCE PROJECT
Detail Engineering

Design Criteria N°000P-GD-006

Piping Design Criteria GD-06

AKER KVAERNER
Av. Nueva Tajamar 481, Piso 19 CLIENT APPROVAL :
Las Condes, Santiago DATE :

REV. DATE BY CHK APPROVAL DESCRIPTION

A 08.Ago.03 RR RB Issued for Internal Coordination

B 29.Sep.03 RR CL FMC/AJL Issued for Riochilex approval
C 19.Jan.04 RPS RRA FMC/AJL Issued for Basic Engineering
D 04.May.0 LCV RRA MJG/FMC/AJL Issued for Final Feasibility Study
4
E 09.Ago.04 RPS RRA MJG/FMC/AJL Issued for Internal Coordination

0 LCV RRA MJG/FMC/AJL Issued for Construction

 Project C-454
Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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INDEX

1.0 SCOPE ..................................................................................................................4

2.0 CODES AND STANDARDS ..................................................................................4

3.0 PIPING DESIGN ....................................................................................................5

3.1 GENERAL...................................................................................................................................... 5
3.2 FLEXIBILITY................................................................................................................................ 6
3.3 CLEARANCES .............................................................................................................................. 7
3.4 ACCESSIBILITY........................................................................................................................... 8
3.5 SUPPORTS AND ANCHORS ....................................................................................................... 8
3.6 THERMAL RELIEF..................................................................................................................... 11
3.7 CONTROL VALVES MANIFOLDS ........................................................................................... 11
3.8 PIPING MATERIAL CLASSES AND IDENTIFICATION ........................................................ 11
3.9 PIPING DRAWINGS ................................................................................................................... 11
3.9.1 Layouts ..................................................................................................................................... 11
3.9.2 Drawings Nomenclature........................................................................................................... 11
3.9.3 Line Marking ............................................................................................................................ 12
3.9.4 Valves Marking......................................................................................................................... 12
3.10 PIPE SIZES AND SIZING ........................................................................................................... 13
3.11 PIPE WALL THICKNESS ........................................................................................................... 17
3.12 CHANGES OF DIRECTION ....................................................................................................... 17
3.13 THREADED CONNECTIONS ............................................................................................................. 17
3.14 BRANCHS ....................................................................................................................................... 18
3.15 INSTRUMENT AIR PIPING ....................................................................................................... 18
4.0 FITTINGS AND FLANGES ..................................................................................18

5.0 VALVES...............................................................................................................19

6.0 GASKETS............................................................................................................20

7.0 PUMPS AND COMPRESSOR PIPING ................................................................20

8.0 COMPRESSED AIR LINES .................................................................................21

9.0 INSULATION AND HEAT TRACING ...................................................................22

10.0 STEAM LINES .................................................................................................22

11.0 UNDERGROUND PIPING ................................................................................22

12.0 PIPING FOR CORROSIVE OR HAZARDOUS SERVICE ................................23

13.0 PIPING FOR SLURRY SERVICE.....................................................................24

14.0 PIPING FOR ELECTROLITE SERVICE...........................................................25

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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15.0 UTILITY SERVICE PIPING ..............................................................................25

16.0 FUELS..............................................................................................................26

17.0 FIRE PROTECTION .........................................................................................26

18.0 BUILDING PLUMBING AND SANITARY SEWERS ........................................26

19.0 VENTS AND DRAINS ......................................................................................26

20.0 PIPING LINE LIST............................................................................................27

21.0 PIPING MATERIALS AND COLOR CODING ..................................................27

22.0 TANKS .............................................................................................................27

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
Detail Engineering, Rev. 0

1.0 SCOPE

This Piping Design Criteria shall be used by design personnel as a guide for design of
piping systems, preparation of drawings, preparing bills of material, and writing of piping
specifications for the Spence Project.

Piping Material Classes, document N° 000P-GD-007 is a part of this Design Criteria.

Special consideration must be taken for equipment and material at the plant site related
to the altitude and climatic conditions. (See 000M-GD-013, Appendix A).

2.0 CODES AND STANDARDS

All piping work shall conform to the Republic of Chile’s Standards, applicable Norms
regulations, codes and ordinances, if there are.

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

ASME - American Society of Mechanical Engineers.

B31.3 “Chemical Plant and Petroleum Refinery Piping” (for piping
within plant boundary limits).
B31.1 “Code for Power Piping”
B31.4 “Liquid Petroleum Transportation Piping System” (for water
pipeline only)
B31.11 “Slurry Transportation Piping System”
ANSI - A13.1 American National Standard Institute - Scheme for the
Identification of Piping Systems
A40.8 National Plumbing Code
ASME - American Society of Mechanical Engineers, Boiler and Pressure
Vessel Code
AWWA - American Water Works Association Inc
API - American Petroleum Institute Standards
ASTM - American Society for Testing Materials
MSS - Manufacturer’s Standardization Society of the Valve and Fittings
Industry
HI - Hydraulic Institute
FM - Factory Mutual Engineering Division Recommended Practices
AWS - American Welding Society
NFPA - National Fire Protection Association
CGA - Compressed Gas Association
NFC - National Fire Codes
UFC - Uniform Fire Code

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
Detail Engineering, Rev. 0

UBC -
Uniform Building Code
UL -
Underwriters Laboratories, Inc. Standards
IAPMO -
International Association of Plumbing and Mechanical Officials,
Uniform Plumbing Code
NCh 283 - Presiones para Diseño y Cálculo de Circuitos Destinados a la
Conducción de Fluidos
NCh 691 - Agua Potable - Conducción, Regulación y Distribución
NCh 1916 - Prevención de Incendios en Edificios - Determinación de Cargas
Combustible
NCh 2/84, NCh 4/84 & NCh 10/94
Normas Eléctricas Oficiales Superintendencia de Electricidad y
Combustibles - Chile.
NACE National Association of Corrosion Engineers (RP0294-94 for
sulphuric acid tanks)

As indicated above the following specifications are applicable to this document and shall
be used in conjunction with this Design Criteria:

• 000B-GD-001-Process Design Criteria

• 000P-GD-007-Piping Material Classes.

• 000M-GD-013-Appendix A – Site Conditions

Equivalent standards of other countries may be accepted subject to Aker Kvaerner’s

review and written approval.

In the event of conflict between the applicable codes and standards, or with drawings and
specifications, the primary referenced code shall govern. Unless otherwise indicated on
the specific section of this specification, the primary code shall be ASME B31.3.

3.0 PIPING DESIGN

3.1 GENERAL

Piping design and arrangement shall follow the appropriate section of the latest edition of
the Standard Code for Pressure Piping ASME B31.3 and the job specifications and
instructions. Where there is a conflict between this guide and the specific job
instructions, the latter shall prevail.

Process design conditions, commodity, pressure and temperature, corrosion allowances,

etc. shall be used to classify each pipeline in accordance with the material specifications
prepared for the project.

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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Material classes specifications have been assigned according to the service, commodity
in the line, the pressure, the temperature, and the corrosion allowance required. See
Piping Material Classes, General Specification 000P-GD-007.

Dynamic loading may be expected when high velocity flow, fluctuating temperature or
pressure, or mechanical vibration (including wind and seismic) conditions exist. Piping
subject to dynamic loading will be designed to ensure that its size, configuration,
mechanical strength, supports, and restraints will prevent excessive stress or vibration.

For start-up, shutdown, or abnormal operation, the pressure or temperature or both may
be allowed temporarily to exceed the basic design pressure. Allowances for pressure
and temperature variations shall be in accordance with the appropriate ASME Code,
B31.1, B31.3, or B31.4.

Cathodic protection for buried steel pipes shall be shown and detailed in drawings, as
required. Details are usually on electrical drawings.

Where a line with a lower pressure rating connects to a line or equipment with a higher
pressure rating, it shall take the specification of the higher rating and including the first
block valve, or and including the second valve when double block valves are used. All
class breaks shall be shown on both the P & ID’s and the piping drawings.

No reduction in line size shall be made on the downstream side of control valves.

Consideration shall be given to the possibility of water hammer occurrence in pipeline

systems. A complete and detailed hydraulic analysis shall be done on the system. The
application and use of slow closing valves, surge arrestors, bleeding of liquid, vacuum
relief valve and even the slowing of the fluid velocity with the use of larger pipe shall be
considered to minimize water hammer.

All branch lines shall be provided with block valves at or near the header.

When design pumps manifolds or other particular facilities, including lined pipes and
fittings, the maximum of uniformity and interchangeability of pieces shall be considered
and spare or replacement parts shall be supplied.

Process yard pipes shall have flanged joint each 250 meters and for process areas each
36 meters.

3.2 FLEXIBILITY

Thermal expansion and contraction of HDPE (High Density Polyethylene) and other
plastic pipes shall be considered in the design based on fluid temperature and/or
environmental conditions.

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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In order to prevent excessive stresses in any piping system, allowance for thermal
expansion and/or contraction shall be made by the use of bends, loops, offsets and
adequate supports. Welded long radius forged fittings may be used where bends are not
practicable. Packed slip joints shall not be used. Expansion provisions shall conform to
ASME B31.3 limited as herein specified.

Expansion joints along the pipe systems shall be avoided, but if required based on layout
restrictions, they shall be fully capable of withstanding at least 1-1/2 times the normal
movement and all working stresses imposed on them by the pressure and temperature of
the contained fluid and the expansion of the pipeline and anticipated transient.

If expansion joints are used, piping upstream and downstream from expansion joints shall
be guided, anchored and supported so no misalignment can occur.

Expansion joints shall be installed on pump discharges to facilitate pump replacement

during maintenance and to relieve pipe stress on the pumps.

Where space permits, an offset-type of expansion bend shall be used and designed in
accordance with ASME B31.3

3.3 CLEARANCES

Minimum vertical clearance for overhead piping shall be as indicated below:

Over railroads 7,050 mm (23 ft)

Over main roadways 6,100 mm (20 ft) minimum
Over secondary roadways 4,300 mm (14 ft)
Over accessways within project limits 3,700 mm (12 ft) with 2,800 mm (9 ft) along
sides for branches

Dimensions as indicated above shall be up to the bottom of the pipes or up to the pipe
racks supporting structures.

Platforms and main walkways shall have generally a minimum lateral clearance of 900
mm (3 ft - 0 in.); 750 mm (2 ft - 6 in.) at manway covers, local walkways and elevated
walkways.

Flanges and drain fittings shall clear the trench floors by 80 mm (3 in) minimum.

Clearance between the side of pipes to the equipment shall not be less than 1,500 mm (5
ft).

Where an access way is required between adjacent equipment, a minimum clearance of

750 mm (2 ft - 6 in.) shall be provided between the outside of flanges to units and
adjacent piping or support columns, etc. Where no access way is required between
adjacent units, 450 mm nominal (1 ft - 6 in.) clearance shall be provided.

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
Detail Engineering, Rev. 0

Any deviations from the clearances mentioned above must be approved by Aker
Kvaerner and shown on the drawing.

3.4 ACCESSIBILITY

Valves and control valve manifolds in overhead and underfloor piping systems and in
piping at process equipment shall be located so they are readily and safety accessible for
operation and maintenance. All manual valves shall be operable from grade or a
platform, or be chain operated.

Passage between unit areas shall be kept free of piping at grade. Lines may be laid
below grade or a ramp may be provided for access.

Where maintenance access precludes the use of forklifts or similar lifting devices,
overhead cranes or hoists shall be utilized. Should piping restrict overhead access,
removable spools shall be provided.

3.5 SUPPORTS AND ANCHORS

Pipe supports, guides, hangers and anchors shall conform to ASME B31.3, limited as
herein specified.

Supports for plastic HDPE (High Density Polyethylene) pipes shall be adequate to
prevent sagging due to the weight of the pipe and its contents. The manufacturer’s
recommendation shall be followed.

Supports and bracing shall be designed to minimize vibration.

Lines for corrosive liquids and slurries that operate intermittently and require draining,
shall be sloped from end to end. The sag at mid span between adjacent supports shall
not exceed the change in elevation between these supports.

Shoes, saddles or other adequate means of protecting insulation shall be provided at all
pipe supports on horizontal runs of insulated piping.

Piping and support systems shall be designed so that longitudinal expansion or side
thrust forces transmitted to structures are minimized.

Pipe guides shall be of the sliding shoe or roller type. Clips are acceptable for small
piping 50 mm (2 in.) nominal size and smaller.

Hangers shall be of the clamp type (preferred) or cleaves depending on size of pipe.
Supports shall provide a structural chair for piping in lieu of hangers where practical. U-
bolt supports attached to the underside of a structural member are not acceptable.

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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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. Welded
circumferential straps attached to the pipe and to the supporting structure are also
acceptable.

Anchors for HDPE (High Density Polyethylene) pipes shall be designed to prevent lateral
displacement and movement at fittings. Anchors will be installed as close as possible to
flanges and changes in direction, in accordance with recommendations of manufacturers.

Alloy steel pipe, rubber or HDPE lined pipes and plastic pipes that cannot be welded to
carbon steel tee anchors shall be anchored by clamping in place.

Insulated pipe shall rest on supports or be suspended by hangers. A tee section shoe or
saddle shall be welded to the pipes to protect insulation.

Expansion bends and piping shall be designed so that flange bolting is not over-stressed.

All lines shall be designed so that expansion forces and moments transmitted to
equipment is less than that allowed by the equipment. Expansion joints and loops shall
be provided as required.

Piping sections requiring frequent dismantling for maintenance, such as for the
installation of blinds or removal of equipment, shall be provided with permanent supports
for the dismantled conditions.

PVC or other plastic pipe shall be supported in accordance with the manufacturer’s
recommendations, or be continuously supported by the use of cable trays or structural
angles in “Vee” position or channels.

All piping supports within the electrowinning tankhouse and corrosive areas shall be 304L
stainless steel or FRP with 304 stainless steel bolts. Care must be taken that such
metallic supports do not provide grounds for stray currents or potentially dangerous short
circuiting possibilities.

Main supports shall be design in coordination with the civil discipline specialists, in order
to considerer the seismic efforts (see Structural Design Criteria No 000C-GD-002).

Pipeways

Pipeways will be sized for present requirements plus 10%, with a minimum of 450 mm
oversized.

When pipeways would be used for future expansions will be sized for present
requirements plus 40% (minimum).

Pipeway bent spacing shall be determined based on the maximum span for the smallest
diameter of pipe on the pipeway, to eliminate intermediate pipe supports to the extent
practical. The recommended minimum pipe size in the pipeway shall be 50 mm (2 in n).

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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Support Spacing

The preferred maximum pipe support spacing for individual lines is governed by Table I
that follows. The simple beam formula shall be used for lines supported by two pipe
supports. The two span formulas shall be used for lines supported by three or more
supports.

Stress and deflection calculations shall be performed where these spans are exceeded,
or where lines are subject to the following conditions:

a. Lines having substantial concentrated loads such as valves, unsupported vertical

risers and branches.

b. Lines having a local reduction in strength caused by the use of special devices.

TABLE I

Nominal Pipe Size Carbon Steel Stainless Steel HDPE

(Water or similar)

(mm) (in) Sch. Span. (m.) Sch. Span. (m) (mm) Span. (mm)
Min. Max. Min. Max. O.D. Max.

20 ¾ 40 2.0 40s 1.5 63 1500

25 1 40 2.1 40s 1.5 75 1650
40 11/2 40 2.7 40s 1.8 90 1800
50 2 40 3.0 40s 2.1 110 2000
80 3 40 3.7 5s 2.7 125 2130
100 4 40 4.3 5s 3.0 140 2250
150 6 40 5.2 5s 4.0 160 2400
200 8 40 5.8 5s 4.6 180 2560
250 10 40 6.7 10s 4.6 200 2700
300 12 Std wt 7.0 10s 4.6 225 2850
350 14 Std wt 7.6 10s 4.6 250 3000
400 16 Std wt 8.2 10s 4.6 280 3000
450 18 Std wt 8.5 10s 4.6 315 3000
500 20 Std wt 9.1 10s 4.6 355 3000
600 24 Std wt 9.8 10s 4.6 1000 3000

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Piping Design Criteria GD-06
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3.6 THERMAL RELIEF

Relief valves or rupture disc shall be provided to protect blocked-in piping systems or
sections of piping systems from pressure generated by fluid thermal expansion as
required by Code and as shown on the P & ID’s.

3.7 CONTROL VALVES MANIFOLDS

Control valve installations shall be evaluated according to service, and bypasses shall be
provided only when necessary, as shown on the P&ID’s.

Where the control valve is line size, the block valves shall be line size. Where the control
valve is smaller than line size, a pressure drop study shall be made and where possible,
the block valves shall also be the same size, as the control valve.

Bypass valves shall be sized to have a flow coefficient (Cv) at least equal to that of the
fully opened control valve. The bypass valve shall be the throttling type of valve as
specified in Piping Material Classes 000P-GD-007, according to the service commodity
and material class. The particular drains shall be installed between the upstream block
valve and the control valve.

3.8 PIPING MATERIAL CLASSES AND IDENTIFICATION

The design temperature, pressure and the service commodity in the line determine the
line material class. The material class shall be identified as illustrated in paragraph 3.9.3.
Piping material will agree with document GD-01 “General Design Criteria”.

3.9 PIPING DRAWINGS

3.9.1 Layouts
Piping layouts shall be in sufficient detail to clearly indicate all crossovers, clearances,
intersections, anchors, supports, expansion provisions, special equipment, and
connections to apparatus. Single line layouts shall be used as much as possible. Piping
drawing scale shall be 1:50 (1/4 in = 1 ft). Underground piping drawings may be drawn to
1:100 (1/8 in = 1 ft) or the plot plan scale. Exception: Process or utility piping intended
for field route may be drawn on 1:2000 or on an existing drawing to show general routing
guide.

3.9.2 Drawings Nomenclature

Abbreviations and symbols used on drawings are listed on the project process and
instrument piping legends.

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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3.9.3 Line Marking

Line markings shall be done on piping drawings by lettering adjacent to the line, repeated
sufficiently to designate the entire line. Each line shall be designated for design purposes
with symbols indicating the facility number where line originates, the service commodity,
line number, piping class and line size in inches. For service commodity listing and
piping class, see 000P-GD-007. The following example illustrates the method of line
marking:
050-NN-8”-XX-001-Y

050 - Area / facility number

NN - Fluid Designation (service commodity)
8” - Line Size in inches ( * )
XX - Piping Material Class (See 000P-GD-007)
001 - Sequential line number by area
Y - Special characteristic of line (insulated or not, heat traced
or not, internal rubber lined, etc)

(*) For plastic pipes (HDPE) shall also use line size in inches, according to equivalence
shown on Table II.

3.9.4 Valves Marking

Valves markings shall be shown on drawings by numbers. The following example

illustrates the method of valves marking:

D” – XXXX- VVYYYY

Where :

D” = Valves size in inches

XXXX = Valve code (**)

VVYYYY = Sequencial valve number for all project

(**) Valve code indicates valve type and material

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Piping Design Criteria GD-06
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TABLE II
DIAMETERS EQUIVALENCE FOR DIFFERENT PIPING CLASSES
NOMINAL CARBON STAINLESS HDPE CPVC or PVC
DIAMETER STEEL STEEL
(in) N. D. (O. D.) N. D. (O. D.) (mm) (1) (mm)
(mm) (mm)
½ 15 (21.30) 15 (21.30) 20 15
¾ 20 (26.70) 20 (26.70) 25 20
1 25 (33.40) 25 (33.40) 32 25
1½ 40 (48.30) 40 (48.30) 50 40
2 50 (60.30) 50 (60.30) 63 50
3 80 (88.90) 80 (88.90) 90 80
4 100 (114.30) 100 (114.30) 110 100
6 150 (168.30) 150 (168.30) 180 150
8 200 (219.10) 200 (219.10) 225 200
10 250 (273.10) 250 (273.10) 280 250
12 300 (323.90) 300 (323.90) 315 300
14 350 (355.60) 350 (355.60) 355 350
16 400 (406.40) 400 (406.40) 400 400
18 450 (457.00) 450 (457.00) 450 450
20 500 (508.00) 500 (508.00) 500
22 550 (559.00) 550 (559.00) 560
24 600 (610.00) 600 (610.00) 630
28 700 (711.00) 700 (711.00) 710
30 750 (762.00) 750 (762.00)
32 800 (813.00) 800 (813.00) 800
36 900 (914.00) 900 (914.00) 900
40 1,000 (1016.00) 1,000 (1016.00) 1,000

(1) O.D., Based on DIN Standards for HDPE.

3.10 PIPE SIZES AND SIZING

All piping shall be in accordance with the Piping Material Classes Nº 000P-GD-007.
Except for lines in which velocities are of critical importance, the following nominal pipe
sizes shall be avoided: 3/8-in, 1-1/4-in, 2-1/2-in, 3-1/2-in, 5-in, and 7-in.

Buried lines shall have a minimum size of 50 mm (2 in).

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With the exception of instrument leads, the minimum size of a line to be run overhead
shall be 25 mm (1 in) unless otherwise approved by Aker Kvaerner. This size may be
reduced to 19 mm (3/4 in) where the run is not over 6100 mm (20 ft) in length and
connecting to steam traps or moisture traps, hose connections or similar short runs.

Valves

• Pipeline block valves shall be the same size as the line unless calculation indicates
otherwise. In no case shall the pump suction valve be smaller than the size of the
pump inlet. Valves on pump discharge piping shall be the same as the line size.

• Block valves (root valves) at main line takeoffs shall meet the specification for the
main line.

Water and Clear Liquids Process Lines

• Long lines shall be sized by applying good design practices with consideration given
to the economics involved.

• Flanged joints shall be provided for dismantling long lines, 250 m maximum intervals.

• Clear liquid lines shall be sized so the velocity is low for small sizes, increasing in
proportionate amounts for larger sizes. The NPSH calculation shall always be
considered for the pumps suctions.

• All service lines shall be sized so that pressure does not drop below minimum
requirements at the end of the most resistant branch line with design flow in that line.

• Branch lines shall be sized based on pressure drop available. When the velocity
based on pressure drop available exceeds the recommended velocities or if the
excess pressure is objectionable, a flow restriction orifice shall be provided and the
line size will be based on recommended velocities.

• Generally, fluid velocity for water and similar viscosity fluids,shall be following:

Pipe Diameter <= 10” 12” to 24” >24

(m/s) (m/s) (m/s)

Suction Pump 0.5 to 1.0 1.0 to 1.5 1.2 to 1.6

Discharge Pump &

Gravity Pipes 1.0 to 1.5 1.5 to 2.2 2.0 to 2.5

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• Fluid velocity for lines between SX settlers and suction lines of solvent extraction
mixer pumps shall be less than 1.0 m/s and will have a pressure drop of not more
than 1.00 kPa/100 m.

Steam and gases Lines

• Steam velocity shall be in the 25 to 35 m/s (82 to 115 ft/sec) range. Pressure drop
shall be limited to 10% of the initial/upstream pressure.

• Air compressed lines shall be sized with a velocity of 8 to 12 m/s (5 to 7 m/s in case
Pipeline) for main pipes and 20 m/s, as a maximum for branch. The maximum
pressure drop will not exceed 10 percent of the initial line pressure, with full capacity
being delivered at the end of the line.

• For air Blower line (low pressure), shall be sized with a velocity of 4 to 5 m/s and a
maximum drop pressure will not exceed 5 % of the initial line pressure.

• Moisture of steam and gases lines will be handled by “drip legs” and automatic
moisture traps.

Sulfuric Acid Lines

• Fluid velocity for concentrated sulfuric acid shall be equal or less than 0.5 m/s (1.6
ft/sec) in case of carbon steel pipe and 1.0 m/sec for stainless steel pipes.

Organic Lines

• Velocity through the pipe for organic fluid shall not exceed 1,2 m/sec in pumped pipes
and 1.0 m/s for interstage SX pipes . The velocity shall be verified with V2d and shall
not exceed 0.64 (V is flow velocity in m/s and d is pipe diameter in m).

• In the organic conduction, made of non-conductive pipes, the installation of a suitable

length of earthed metal pipe shall be considered.

Design Flow

Design flow for piping systems will be based on Process Flowsheet quantities as follows,
unless otherwise specified by Process or by the Project Engineer:

• Utility Services

Design flow = Process Flow Diagram Design Flow

• Process flow

Design flow = Process Flow Diagram Design Flow

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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Hydraulic Calculations

• Head losses calculations for solutions, Hazen – Williams equation, in accordance with
the following coefficients.

C (carbon steel) = 100

C (stainless steel) = 120
C (HDPE) = 140 – 150

• Head losses calculations for gases and viscous solutions, Darcy-Weisbach equation,
in accordance with the following roughness.

E (carbon steel) = 0.1 mm

E (stainless steel) = 0.05 mm
E (HDPE) = 0.007 mm

Calculations of particular head losses in valves and fittings, will be estimated in

accordance with the number of velocity heads losses in each fitting or based on the
valves flow coefficients.

Aqueducts calculations, Manning equation, with the following coefficients:

n (carbon steel) = 0.013

n (stainless steel) = 0.012
n (Plastic pipe) = 0.011
n (HDPE lined channel) = 0.013 – 0.014

Safety Factors

Pumps (pump sizing):

− The flows are the “nominal flow” and “design flow” from the Process flow
diagrams.
− The calculated head losses based on “nominal flow” will be affected by the factor
1.2, as a maximum of 7 m of liquid column.
− The static head will be affected by the factor 1.1, as a maximum of 5 m.
− The calculated head losses, based on “design flow”, will be not affected by
safety factors.
Gravity Flows
− Pressurized pipes: The calculated head losses will be affected by the factor 1.2
− Aqueducts: The maximum calculated flow height will be a 60% of the diameter of
the pipe.
- For open channels the freeboard will be 1.5 velocity heads, as a minimum.

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
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3.11 PIPE WALL THICKNESS

Except as noted, pipe wall thickness shall be calculated in accordance with ASME B31.3
latest revision, and to this a corrosion allowance shall be added. The corrosion allowance
shall be as specified in 000P-GD-007, Piping Material Classes.

For all pipes the calculated working pressure shall be less than the maximum pressure
shown on Piping Material Classes, 000P-GD-007.

As an exception, the working pressure for HDPE pipes shall be 80% of maximum
pressure shown on Piping Materials (or 80% of manufactures nominal pressure). If the
HDPE piping system requires more working pressure, a carbon steel pipe with HDPE
lining can be used. The design pressure for leach area pumped pipelines will be the
water hammer calculated pressure. The shut off pumps maximum pressure shall not be
considered for pipes wall thickness calculations.

3.12 CHANGES OF DIRECTION

Changes in direction on piperacks or parallel pipe runs shall not be made on a horizontal
plane. Allowances shall be made in piperacks to allow for the changes in elevation.

When using steel pipe, changes in direction shall be made with fittings or bends. Butt-
welding elbows are preferred over bends.

All butt-welding elbows shall be of the long-radius type unless otherwise noted. Short
radius elbows shall be avoided unless space limitations require their use.

The use of reducing elbows shall be limited to installations where space does not permit
the use of a long radius elbow and a weld reducer.

Pipe bends can be used for hydraulic oil piping, the bends shall have a minimum bending
radius of five times the nominal pipe diameter, except where noted on drawings. If space
does not permit, bends of three-diameter may be used with the approval of the Aker
Kvaerner’s design supervisor.

One-weld mitre elbows may be used for large air compressor intake lines. Multiple-weld
mitre elbows (see AWWA C-208) may be used for low pressure services and auxiliary
vent and flare lines. Pressure rating of mitred elbows and bends shall be verified by Aker
Kvaerner and shall meet ASME B31.3 requirement.

3.13 THREADED CONNECTIONS

Threaded connections shall not be used on pipes over 50 mm (2 in) diameter.

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Aker Kvaerner Design Criteria N° 000P-GD-006
Piping Design Criteria GD-06
Detail Engineering, Rev. 0

Provide adequate unions to facilitate assembly and disassembly of threaded connections.

Provide adequate clearances for removal and installation of threaded valves without
disassembling valve.

Threaded connections are not permitted in hydrocarbon and sulfuric acid service, except
for:

• Threaded pressure gauges.

• Threaded instrument meter bodies.
• Small thermal relief valves.
• Equipment connections, which cannot be obtained other than threaded.
• Where threaded connections are specifically required and found acceptable to code.

The use of all-welded systems decreases accessibility for maintenance and inspection of
piping. The piping designer shall provide piping systems with sufficient flanges or unions
for maintenance and inspection.

3.14 BRANCHS

The design and use of welded branch connections shall conform to the requirements of
ASME B31.3 and Piping Material Classes, Specification 000P-GD-007, supported by
calculations.

Where vibration may be anticipated, joints shall be butt-welded and valves shall be
flanged.

3.15 INSTRUMENT AIR PIPING

Field routed instrument air branch lines shall be provided with accessible root valves at
the header. The responsibility for providing the branch connection and the root valve lies
with the piping discipline, responsibility for downstream piping tubing or devices lies with
the instrumentation discipline.

Branch instrument air piping shall be taken off at the top of the header.

4.0 FITTINGS AND FLANGES

Screwed fittings shall be Class 300 per ANSI B16.3, “Malleable Iron Threaded Fittings”,
minimum.

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Piping Design Criteria GD-06
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Reducing tees may be used for connections provided the branch is not reduced more
than two pipe sizes. Where used, it shall be indicated on the drawings. HDPE reducing
tees shall not be used.

HDPE fittings will be molded up to 10” diameter and will be miters for diameter greater
than 10”.

Flange types are denoted on individual piping material classes specifications. The bore
of welding neck flanges shall match the inside diameter of the pipe.

Steel flanges mating with ANSI Class 125 iron, FRP, plastic and rubber-lined pipe flanges
shall be the corresponding ANSI Class 150 flat face with full face gaskets. Gasket is
required on rubber faced joints. Steel flanges mating with ANSI Class 250 cast iron
flanges shall be ANSI Class 300 raised face.

Facing for flanges in joints containing spiral wound gaskets shall be smooth finished to a
roughness measurement in the range of 3.2 to 12.5 microns (125 to 500 micro in) RMS.

Forged steel welding fittings are preferred over cast iron fittings. Cast steel welding
fittings or flanges shall be considered where the cost advantage is appreciable and they
meet specification.

The design will only consider standard fittings. Special fittings shall be approved by Aker
Kvaerner piping lead.

Permanent dead ends in pipelines are prohibited in hydrocarbon or corrosive service.

To lined pipes and fittings the maximum of uniformity and interchangeability of pieces
shall be considered

5.0 VALVES

Gate valves, ball valves or plug valves shall be used in wide open or closed (on-off)
service, gate valves will not be used in throttling service. Tight shutoff valves shall be
used on low temperature light hydrocarbons, gas, propane, fuel oil, compressed air piping
and in other services where required.

For throttling service, use globe valve for sizes up to 100 mm (4 in), butterfly valves for
150 mm (6 in) and larger. For low pressure slurry application, pinch valve shall be used
for throttling.

The use of angle valves shall be avoided, except for fire protection use.

Unless otherwise indicated on the drawings, the valves as shown at Table III, shall be
furnished with a manual, variable position gear operator.

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Piping Design Criteria GD-06
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TABLE III

ANSI Class Size (in)

Gate Valves 150 350 mm (14”) & larger
300 300 mm (12”) & larger
Globe Valves 300 200mm (8”) & larger
Ball Valves 150 150mm (6”) & larger
300 150 mm (6”) & larger
Plug Valves 150 150mm (6”) & larger
(Non-Block & Bleed) 300 150 mm (6”) & larger
Butterfly Valves 150 200 mm (8”) & larger

6.0 GASKETS

Non-asbestos composition gasket suitable for the conveyed fluid, 1.6 mm (1/16”) thick,
shall be used for temperatures up to 260 °C (500 °F), on raised face flanges.

Spiral wound gasket per API 601 standard with centering ring like Flexitallic Style CG or
an equivalent shall be used for temperatures above 260 °C (500 °F).

For ANSI Class 125 flanges mating with cast iron valves or pumps with cast iron casings,
3.0 mm (1/8 in) thick elastomer full face gaskets shall be used. Ring gaskets 1.6 mm
(1/16 in) thick shall be used with ANSI Class 250 cast iron flanges.

On vacuum lines operating at 380 mm (15 in) Hg and higher, flat faced flanges and 3.0
mm (1/8 in) with full face red rubber gaskets shall be used.

Granular teflon gaskets shall be used for corrosive service. EPDM shall not be
employed for gaskets, valve seats and linings if there is any possibility of contact with
organic solution or entrainment, Viton or Buna N shall be used.

7.0 PUMPS AND COMPRESSOR PIPING

Both suction and discharge piping shall be supported so that no load is transmitted to the
equipment.

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A temporary strainer shall be provided in all pump suction lines during construction start-
up. The strainer shall be installed between the block valve and the pump. Piping shall be
arranged to provide easy removal for cleaning and inspection.

Discharge lines of reciprocating pumps and compressors shall be considered as being in

shock service. Special consideration shall be given to the rating of valves and fittings.
The lines shall be carefully anchored.

Positive displacement pumps shall be provided with a full capacity relief valve between
the pump discharge and the first block valve. Discharge from the relief valve shall be
routed back to the source, not back into the pump suction, unless otherwise specified.

Overhead pump suction lines shall be arranged to drain from the equipment towards the
pump.

Where two or more centrifugal pumps have a common manifold, a check valve shall be
installed in the discharge of each pump. A check valve shall be installed in the discharge
of a centrifugal pump where back pressure on the discharge side is continuous and could
cause the pump to run backwards. The check valve shall be placed between the pump
and the block valve. Where the size of the discharge line will not permit block valves to
be installed adjacent to check valves, they shall be placed in overhead runs.

All suctions to centrifugal pumps shall be installed in accordance with the

recommendations of the Hydraulic Institute. Reducers shall be adjacent to nozzles, using
eccentric reducers level-on-top in horizontal suctions of clear liquids.

Connections to end suction pumps shall be made with pipe spools to permit access to the
pump. Flanged elbows may only be used if the 10 – diameters straight run rule shall be
observed.

Low points in suction and discharge lines of pumps shall be provided with valved drain
connections.

Flexible rubber joints at the suction and discharge shall be considered on low pressure
systems.

Deviations from the above for special cases of pump service may be made and shown on
piping drawings.

Pressure gage connections shall be provided in all pump discharge lines and shall be
located between the pump and the first valve.

8.0 COMPRESSED AIR LINES

Main compressed air lines shall be installed with a slope in the direction of flow of not less
than three tenths of one percent (0.3 %).

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Piping Design Criteria GD-06
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Moisture drain traps should be installed at low points of main air lines.

9.0 INSULATION AND HEAT TRACING

Insulation as required shall be in accordance with Specification 000P-GC-013. Heat

tracing systems shall be of the temperature limiting electrical heat tracing cable type,
complete with thermostatic controls.

10.0 STEAM LINES

Steam lines adjacent to the boiler only shall be designed in accordance with ASME
B31.1. ANSI B31.3 covers steam lines in the plant.

Branch steam lines shall be taken off at the top of the steam main and shall be provided
with a shutoff valve adjacent to the main.

Main steam lines shall be installed with a slope in the direction of flow of not less than
one tenth of one percent (0.1%). No deflection pockets between supports will be
permitted.

Steam traps shall be located at low points in the system or at intervals as specified on
drawings. Traps shall be provided with a test valve, strainer and check valves.

Steamout connections shall be provided with double block and bleed.

All hot piping shall be checked for excessive thermally induced stress forces and
movement.

Discharge piping of safety valves shall avoid the use of elbows and reductions and shall
be designed in accordance with Appendix II of ASME B31.1. Means of collecting
condensate from safety valve discharge stacks shall be provided to discharge the
condensate safely.

11.0 UNDERGROUND PIPING

All buried steel pipe, including lines in sand filled trenches, where the normal flow
temperature is below 65 °C (150 °F), shall be protected from external corrosion as shown
in the individual piping material classes.

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Sleeves made of steel pipe, HDPE culvert material or standard corrugated culvert shall
be used for lines, 300 mm (12 in) and larger, crossing under railroads, roads and areas
where concentrated loads may occur.

All pressure pipe with slip-type joints, mechanical joints or couplings, except drainage and
sewer lines, shall be anchored at ends of runs and at turns with concrete thrust blocks.
Consideration shall be given to the use of positive locking mechanical joint special
anchoring tees and connecting pieces for fire hydrant and hydrant valves installation to
eliminate anchor blocks at hydrant ends.

All underground piping shall be supported for the full length by the bottom of the trench,
except where clearance for joints must be provided. All buried pipe installation details
shall be shown on drawings.

Where pipe with slip-type joints are used, block valves in branch lines shall be anchored
to prevent separation.

Drainage and sewer lines, except chemical waste lines, installed below the floor slabs or
paved roadways, shall be PVC, type 1, grade 1, schedule 80.

Where pipes are buried in traffic area, a minimum of 1,200 mm (4 ft) of cover shall be
provided.

The minimum size of buried pipe shall be 50 mm (2 in).

For underground pipes concrete signals must be considered, the detail of fluid in the
pipes will be shown.

12.0 PIPING FOR CORROSIVE OR HAZARDOUS SERVICE

All underground piping containing corrosive and other hazardous material shall be
sleeved with corrosion resistant plastic pipe sleeves or double walled pipe. The
secondary containment sleeve or outer wall of double walled piping shall drain into pits or
sumps. The pipes and its sleeves shall be sloped for self draining.

The aboveground pipes for corrosive or hazardous solutions shall be sleeved after a risks
analysis.

Any piping containing corrosive or hazardous material shall be routed in trenches, if they
must be routed below grade level. Otherwise, laying the lines underground will require
secondary containment with leak detection system. Pipe trenches containing fluids
routed in the same trench shall not cause evolution of toxic gases due to possible
leakage of any of the piped fluids.

Lines containing corrosive or hazardous material shall be sloped so that they can be
completely drained.

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Vent and drain connections installed to facilitate hydrostatic testing shall be plugged and
sealed after testing.

All flanged joints on acid piping shall have covers to prevent liquid sprays from defective
gaskets, etc. For the discharge of sulfuric acid tanks, double valves for shut-off shall be
considered.

13.0 PIPING FOR SLURRY SERVICE

Slurry piping shall be designed in accordance with ASME B31.11 and with minimum
amount of change of direction to reduce abrasion and chances of plugging. Where
possible, slurry shall flow in a direct line from one equipment item to another. Valving for
this application shall be avoided.

Low points in slurry service shall be avoided. However, if a low point cannot be avoided,
a low point drain shall be provided.

If possible, rubber hoses or pipe bends shall be used in place of elbows. Minimum bend
radius shall be five (5) pipe diameters.

Piping shall have victaulic couplings and be arranged and supported to allow easy
dismantling for maintenance purposes.

Flushing connections shall be provided as shown on the P & ID’s and on all pump suction
and discharge lines and at other points in the system where the possibility of plugging
exists.

Slurry lines shall be sloped 2% (1/4” per ft) to permit self-draining unless otherwise noted
on the P & ID. In no case shall the slope be less than 1% (1/8” per ft).

Pump suction lines shall be minimum length and no bends or elbows shall be used.
Removable suction spool shall be provided for impeller maintenance. The use of valves
in pump suction lines shall be avoided, but if required, the valve shall be knife type.

When a standby pump is included in the design, the piping joining the operating pump
and its spare shall be designed to prevent plugging of the non-operating portion of the
piping and shall be provided with water flush connections and drains.

For hydraulic calculations, the critical deposition velocity shall be estimated using
reference such as WASP:

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VL= F’L [2gD(s -l)/ l]0.5 (d50 / D)1/6, Where:

• VL = Critical deposition velocity (m/s)

• g = Gravitational acceleration (m/s2)
• D = Inside diameter (m)
• s = Density of the transported solid (gr/cc)
• I = Density of the transported liquid (gr/cc)
• d50 = Particles size(microns)
• F’L = Parameter, depends on size and concentration solids

F’L = 3.322 CV 0.21 with Cv = Concentration of solids by volume

The min. velocity shall be 10% greater than critical deposition velocity,

The max. velocity shall be 4.0 m/s in order to avoid accelerated wear due to abrasion.

14.0 PIPING FOR ELECTROLITE SERVICE

All piping in tankhouse must be below busbar runs.

All electrolyte piping in the tankhouse shall enter and leave through the electric null points
below the back busbars and the design must assure isolation.

The electrolyte overflow from cells, shall be transported with a free surface flow (see
gravity flows, as aqueducts on section 3.10) and the pipes for this flow will design with
more than one vents for each line.

15.0 UTILITY SERVICE PIPING

Hose stations for air and water shall be provided at approximately 24-meter (80 ft)
intervals inside the process buildings.

Supply lines to hose stations shall be 25 mm (1 in) diameter and shall have a shut-off
valve at the hose station. Hoses shall be 30 meter (100 ft) lengths with quick coupling.

Sediment legs, blowdown valves and drain traps shall be installed in air lines at low
points and dead ends.

Branch utility lines shall have block valves adjacent to the main line. In general, these
valves shall be accessible.

All gaseous utility branch lines shall be taken off the top half of supply headers.

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Drain connections shall be provided in all above ground liquid lines so that they can be
completely drained.

16.0 FUELS

Liquefied petroleum gas installations shall conform to the “Standard for the Storage and
Handling of Liquefied Petroleum Gases” as outlined in NFPA Standards 30 and 58, and
Chapter 43 of Factory Mutual’s, “Industrial Loss Prevention”.

Fuel oil installations shall conform to NFPA Standards 30, 31 and 395.

The Chilean codes (Decreto 90), regulations and ordinances shall be considered.

17.0 FIRE PROTECTION

See Fire Protection Design Criteria, 000P-GD-106.

18.0 BUILDING PLUMBING AND SANITARY SEWERS

See “Criterio de Diseño Para Instalaciones Interiores de Edificios”, 000P-GD-206

19.0 VENTS AND DRAINS

High points of lines shall be provided with vent connections. Vent connections shall be
located, where possible, in accessible locations adjacent to platforms or structural
members.

Drains shall be provided at all low points of the system. Drains shall be provided at each
point where liquid might form upstream of a control or shutoff valve during operation or
cleaning.

All drains emptying into open funnels shall terminate approximately 50 mm (2”) above the
top of the funnels.

Drain piping shall be oversized to facilitate a quick emptying of lines.

Valved drains shall be provided for the following:

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• Upstream side of control valves for corrosive and hot process services.
• Above all block or check valves in vertical steam, acid or caustic lines.
• Drain piping for steam trap shall be insulated to 2,500 mm above grade or floor level.

20.0 PIPING LINE LIST

A Piping Line List shall be prepared for the design of process and utility lines. Vents and
drains shall be omitted. Line List will include: start of line, end of line, P&ID, test pressure
and type of insulation.

21.0 PIPING MATERIALS AND COLOR CODING

Material specifications for pipe, valves, fittings and specialty items shall conform and be
in accordance with General Specification 000P-GD-007, “Piping Material Classes.”

Color coding for pipes will be detailed in General Specification 000A-GC-002, “Carta de
Colores “.

22.0 TANKS

All open tank capacities shall be calculated to include a free board of 300 mm to 450 mm.

All tanks shall be provided with a manhole and with vents, drains and overflow connection
pipes.

The operating volume of tanks, will be calculated between the bottom of the overflow and
the minimum operating liquid level.

The minimum diameter of vents and drains, are as follows:

Tank Volume Vent Drain

(m3) Diameter, mm Diameter, mm
(in) (in)
up to 5 50 (2) 50 (2)
5.1 15 75 (3) 75 (3)
15.1 50 75 (3) 100 (4)
50.1 100 100 (4) 100 (4)
100.1 200 100 (4) 150 (6)
200.1 500 100 (4) 200 (8)
500.1 1,200 150 (6) 200 (8)
more than 1,200 150 (6) 250 (10)

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The vents shall be verified with flows of inlet and outlet pipe.

Consideration shall be given to the use of non-metallic materials for tank construction
where required by corrosive conditions.

Tanks of suction pumps shall be sized considering one minute of the retention time,
based on the design flow.

Non-pressure tanks shall be calculated in accordance with API 650 Standard. The
pressure tanks shall be calculated in accordance with ASME, Boiler and Pressure Vessel
Code.

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