Anexo 25 MQ11-02-DC-1100-PD0004 - RX

Anglo American Quellaveco S.A.
MQ11-02-DC-1100-PD0004
Project Quellaveco Date 02-Jun-2020
Contract Q1CO Page 1 of 28
Rev. X
FRESH WATER PIPELINE DESIGN CRITERIA
This document has been revised as indicated below and described in the revision record on the following
page. Please destroy all previous revisions.
Revision Date Originator’s Name and Reviewed/Approved by Pages

Initials Name and Initials
A 14-Abr-2015 Juan Fuentes / JF Rodrigo Barra / RB 29
B 21-Jul-2015 Juan Fuentes / JF Rodrigo Barra / RB 28
X 02-Jun-2020 Leopoldo Gravel / LGgra2
0855
Digitally signed by
gra20855
Date: 2020.06.02
23:16:09 -04'00'
José I. García / JIG 28
APPROVERS SIGNATURES DATE
gar19
Digitally signed
by gar19098
Discipline Lead José I. García Date:
098 2020.06.02
23:14:33 -04'00'
Engineering Manager Freddie Colón gam54665

Digitally signed by gam54665
Date: 2020.06.03 14:42:04
-04'00'
Area Manager Pablo Lattus
Project Manager Craig Lafortune
Client: José Mendivil
Issued for : Design Construction X Other VOID
Piping
Anglo American Quellaveco S.A. MQ11-02-DC-1100-PD0004
Rev. X
Record of Revisions
Rev. No. Date Description
A 14-Abr-2015 Issued for Internal Review
B 28-Jul-2015 Issued for Client Approval
X 02-Jun-2020 VOID
Piping
Rev. X
Contents
Section
1.0 GENERAL ..................................................................................................................................................... 5

1.1. Scope .................................................................................................................................................... 5
1.2. Codes and Standards .......................................................................................................................... 5
1.3. Design Criteria .................................................................................................................................... 7
1.4. Technical Specifications ..................................................................................................................... 7
1.5. Drawings.............................................................................................................................................. 8
1.6. Studies.................................................................................................................................................. 8
1.7. AA (Anglo-American Standards) ...................................................................................................... 8
1.8. Others .................................................................................................................................................. 8
2.0 SYSTEM DESCRIPTION ............................................................................................................................ 9

2.1. General ................................................................................................................................................ 9
2.2. Basis of Design .................................................................................................................................. 11
3.0 FACILITY DESIGN ................................................................................................................................... 12

3.1. General .............................................................................................................................................. 12
3.2. Air Valves and Drains ...................................................................................................................... 12
3.3. Pipe Supports and Anchors ............................................................................................................. 13
3.4. Cleaning and Inspection Stations .................................................................................................... 13
3.5. Pump Stations ................................................................................................................................... 14
3.6. Transfer Tank TAG 1140-TK-001 .................................................................................................. 15
3.7. Fresh water Transfer Tank TAG 1140-TK-002 ............................................................................. 15
4.0 PIPELINE DESIGN .................................................................................................................................... 16

4.1. General .............................................................................................................................................. 16
4.2. Routes and Slopes ............................................................................................................................. 16
4.3. Pipe Supports and Anchors ............................................................................................................. 17
4.4. Hydraulic Design .............................................................................................................................. 18
4.5. Mechanical Design ............................................................................................................................ 19
5.0 CONSTRUCTION ...................................................................................................................................... 23

5.1. General .............................................................................................................................................. 23
5.2. Cold Bending of Pipe on Site ........................................................................................................... 23
5.3. Elbow or Bend Restrictions (cast or hot bent fittings) of the Line Pipe ....................................... 23
5.4. Restrictions on Pipe located at the Installations ............................................................................ 24
5.5. Restrictions on Pipe located at High Sloping Sectors .................................................................... 24
5.6. Production Process ........................................................................................................................... 24
Piping
Rev. X
6.0 SINGULARITIES ....................................................................................................................................... 24

6.1. Drains ................................................................................................................................................ 24
7.0 INTERNAL AND EXTERNAL COATING ............................................................................................. 24

7.1. Internal Cleaning and Inspection Systems ..................................................................................... 25
7.2. Corrosion Control............................................................................................................................. 25
8.0 PIPING OPERATION ................................................................................................................................ 28

8.1. General .............................................................................................................................................. 28
Piping
Rev. X
1.0 GENERAL
1.1. Scope
These design criteria establish the engineering standards and practices to be followed in the
design of the fresh water pipeline for the Quellaveco Project, owned by Anglo American
Quellaveco S.A. (AAQSA). This document will be applied to the design of the pipeline
pump stations and valve selection. It also defines the coating to be applied to the pipe,
avoid corrosion. The pipeline will be used to transport fresh water from sources at the
Vizcachas and Titire rivers to the storage ponds located at Caracoles hill – approximately
3,850 meters above sea level (m.a.s.l.) which eventually will feed the Papujune fresh water
tank (TAG 3930-TK-001).
These design criteria do not apply to control systems, electrical and construction systems.
1.2. Codes and Standards
The design of the piping systems shall conform to generally accepted engineering practices,
codes and standards, in their latest version, issued by the following institutions:
ASME American Society of Mechanical Engineers

 ASME B31.4 Pipeline Transportation Systems for Liquid
Hydrocarbons and other Liquids.
 ASME B16.20 Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-
Wound, and Jacketed.
 ASME B16.5 Pipe Flanges and Flanged Fittings.
 ASME B16.47 Large Diameter Steel Flanges.
 ASME B16.9 Factory Made Wrought Steel Buttwelding Fittings.
 ASME B16.49 Factory Made Wrought Steel Buttwelding Induction
Bends for Transportation and Distribution Systems.
 ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges.
 ASME B16.49 Factory-Made, Wrought Steel, Butt-welding Induction
Bends for Transportation and Distribution Systems.
 ASME BPVC-VIII Boiler and Pressure Vessel Code (BPVC), Section VIII,
Division 1: Rules for Construction of Pressure Vessels
ASTM American Society for Testing and Materials

 ASTM A193 Alloy-Steel and Stainless Steel Bolting for High
Temperature or High Pressure Service and Other Special
Purpose Applications
 ASTM A194 Standard Specification for Carbon and Alloy Steel Nuts
for Bolts for High Pressure or High Temperature
Service, or Both
Piping
Rev. X
 ASTM A307 Standard Specification for Carbon Steel Bolts, Studs,

and Threaded Rod 60 000 PSI Tensile Strength.
 ASTM D3350 Standard Specification for Polyethylene Plastics Pipe
and Fittings Materials.
 ASTM D638 Tensile Properties of Plastics.
 ASTM F-714 Standard Specification for Polyethylene Plastic Pipe
Based on Outside Diameter.
AWWA American Water Works Association
 AWWA C210 Liquid-Epoxy Coating Systems for the Interior and
Exterior of Steel Water Pipelines
 AWWA C203 Coal-Tar Protective Coatings and Linings for Steel
Water Pipelines – Enamel and Tape Hot Applied.
 AWWA D100 Welded Steel Tanks for Water Storage
 AWWA D102 Coating Steel Water-Storage Tanks
 AWWA M51 Air release, Air/Vacuum & Combination air Valves
AWS American Welding Society
 AWS A3.0 Standard Welding Terms and Definitions Including
Terms for Adhesive Bonding, Brazing, Soldering,
Thermal Cutting, and Thermal Spraying.
 AWS A5.1 Specification for Carbon Steel Electrodes for Shielded
Metal Arc Welding
 AWS A5.2 Specification for Carbon and Low- Alloy Steel Rods for
Oxy-fuel Gas Welding
 AWS A5.5 Specification for Low-Alloy Steel Electrodes for
Shielded Metal Arc Welding
API American Petroleum Institute
 API 5L Specification for Lined Pipe.
 API RP 5LW Transportation of Line Pipes on Barges and Marine
vessels.
 API RP 5LT Recommended Practice for Truck Transportation of Line
Pipe.
 API RP 5L7 Recommended Practice for Unprimed Internal Fusion
Bonded Epoxy Coating of Line Pipe.
 API 6D Specification for Pipeline Valves
 API 594 Check Valves. Flanged, Lug, Wafer and Butt-welding
 API 600 Steel Gate Valves. Flanged and Butt-welding ends.
Bolted Bonnets.
 API 650 Welded Steel Tanks for Oil Storage
Piping
Rev. X
 API 1104 Welding of Pipeline and related Facilities.

 API STD 2000 Venting Atmospheric and Low pressure Storage Tanks.
 API 1102 Steel Pipelines Crossing Railroads and Highways
PPI Plastic Pipe Institute
 TR-09 Recommended Design Factors for Pressure Applications
of Thermoplastic Pipe Materials.
 TN-27 FAQ HDPE Pipe for Water Distribution and
Transmission Applications.
MSS Manufacturers Standardization Society
 MSS SP44 Steel Pipeline Flanges
 MSS SP58 Pipe Hangers and Supports - Materials, Design,
Manufacture, Selection, Application, and Installation
 MSS SP69 Pipe Hangers and Supports – Selection and Application
(ANSI-approved American National Standard)
 MSS SP75 Specification for High-Test, Wrought, Butt-Welding
Fittings.
NACE National Association of Corrosion Engineers

 NACE RP0169 Control of External Corrosion on Underground or
Submerged metallic Piping Systems.
 NACE RP0198 Control of Corrosion under Thermal Insulation &
Fireproofing Materials. A System approach.
 NACE SP0188 Discontinuity (Holiday) Testing of New Protective
Coatings on Conductive Sustrates.
 NACE SP0177 Mitigation of Alternating Current and Lightning Effects
on Metallic Structures and Corrosion Control Systems.
National Electrical Code of Peru - 2006
1.3. Design Criteria
MQ11-02-DC-0000-PD0002 Hydraulic Design Criteria.
1.4. Technical Specifications
MQ11-02-TE-0000-ME0001 Site Conditions Technical Specification.
MQ11-02-TE-0000-PD0001 Especificación Técnica Materiales de Tuberías.
MQ11-02-TE-1000-PD0006 Especificación Técnica Fabricación e Instalación

Pipeline Agua Fresca.
Piping
Rev. X
MQ11-02-TE-0000-PD0010 Especificación Técnica Código de Colores para

Tuberías.
MQ11-02-TE-1000-PD0007 Coal-Tar External Pipeline Protection System.
MQ11-02-TE-000-PD0008 Fusion Bonded Epoxy (FBE) Internal Pipeline

Protection System.
MQ11-02-TE-0000-GA0001 Especificación Técnica de Pinturas.
MQ11-02-TE-1000-PD0032 Technical Specification Pipeline Pig Launchers and

Receivers.
1.5. Drawings
MQ11-02-DR-5400-FS1001 Infrastructure – Fresh water Treatment and Distribution –

Flow Diagram
1.6. Studies
MQ09-09-RE-000-GA0009 “Analysis of Fresh water Corrosivity/Pipe and Lining Test

Analysis” by AguaMarina.
1.7. AA (Anglo-American Standards)
AA REQ 100 Quality Requirements for Suppliers of Critical and Major Equipment.
AA REQ 110 Owners Team Quality Activities.
AA REQ 120 Purchaser Quality Activities.
AA REQ 130 Contract Inspection Requirements.
AA-GTS-00005 AFRG5 Anglo Fatal Risk Standard – Equipment Safeguarding.

AA-GTS-00006 AFRG6 Anglo Fatal Risk Standard – Isolation.
AA-GTS-00007 AFRG7 Anglo Fatal Risk Standard – Working at Heights.
AA-GTS-00008 AFRG8 Anglo Fatal Risk Standard – Lifting Operations.
1.8. Others
United States Department of Interior, Water and Power Resources Service, “Engineering
Monograph N° 41 Air-Water Flow in Hydraulic Structures”.
All of the foregoing documents are referred to in their latest version / revision to date
Piping
Rev. X
2.0 SYSTEM DESCRIPTION
2.1. General
The fresh water transport system will consider two feed sources – the Vizcachas and Titire
rivers.
Independent pumping systems will extract water from both of these sources. These
independent feed pipes will then join at a common header 15 km from the Titire intake.
This main will then transport a flow of water to the transfer tank located at Pelluta hill,
located 21 km downstream the Titire intake and at an approximate elevation of 4.820
m.a.s.l. From this tank (TAG 1140-TK-001), water will gravitationally flow to the fresh
water transfer tank (TAG 1140-TK-002) at km 88,6 from Titire intake and at 3.899,0
m.a.s.l.. This transfer tank location will allow the use of the 30” polyethylene pipe currently
used for construction water transport. This aforementioned existing pipeline ends at the
storage ponds at Caracoles hill and the Quellaveco water tank. The total distance of the
flow is approximately 88,6 km and crosses the peak of the of Pelluta hill at a peak altitude
of 4.820 m.a.s.l.
The fresh water system will be permanently fed by the Titire while flow is available. The
use of water from the Vizcachas river (reservoired during wet season) will be reserved for
periods when the Titire source is not sufficient.
The Titire intake (designed by third party) will be located at approximately 4.342 m.a.s.l.
The feed system will consist of a pump station (Titire river Fresh water Pumps TAG 1120-
PU-001@005). At km 15 this pipe will connect with the pipe coming from the other fresh
water source (Vizcachas river).
A dam for the Vizcachas river (by third party) is at an approximate elevation of 4.343
m.a.s.l. An intake from the output at the river bottom will feed the pump station (Vizcachas
river Pumps TAG 1130-PU-001@008).
A diagram of the fresh water system can be seen in Figure 2.1:
Piping
Project Quellaveco Date 21-Jul-2015
Rev. B
Figure 2.1.-Pipeline Diagram
Piping
Rev. X
2.2. Basis of Design
2.2.1. Titire and Vizcachas Pipelines
The following design critieria have been established for the Titire and Vizcachas
pipelines:
 Pressure Class From ASME class 150 to ASME Class

600
 Design Flow (Vizcachas) 700 L/s (2.520 m3/h)
 Design Flow (Titire) 770 L/s (2.772 m3/h)
 Design Temperature Range -5°C a +25C
 Design Temperature for Water 5°C
 Service Life 29 years
 Design Code ASME B31.4
 Design Factor 0,72
 Pipeline Material API 5L and HDPE PE4710.
 Corrosion Thickness 0,00 mm (plastic and lined pipe)
 External Protection (buried) Coal-Tar enamel according to AWWA
C203
 External Protection (above surface) Liquid Epoxy according to AWWA
C210
 Internal Protection FBE (Fusion-Bonded Epoxy),
according to API 5L7. Use of internal
FBE coating at a minimal thickness of
500±50 microns, based on study
MQ09-09-RE-0000-GA0009, “Analysis
of Fresh water Corrosivity” conducted
by third parties in coordination with
AngloAmerican and supplier
recommendations.
 Cathodic Protection Mixed - impressed-current and
sacrificial anodes. The definition of the
requirement and composition of the
Piping
Rev. X
cathodic protection system will be

within of the electrical discipline scope.
 Induced Voltage Protection Mixed - impressed-current and
sacrificial anodes. Final definition of
requirement and composition of this
protection method will be within of the
electrical discipline scope.
 Installation Mixed – buried sections (for the most
part) and sections above ground.
This basis constitutes the minimum requirements for the pipeline design. The
factors indicated below must also be considered.
The active protection design for corrosion must be coordinated by the piping
discipline.
3.0 FACILITY DESIGN
3.1. General
Design of the facility contemplates the characteristics of the pipeline itself as well as the
other equipment and systems which, together, provide acceptable operative results.
The following design aspects and complimentary equipment shall be considered:
 Pipeline supports and anchors

 Cleaning heads
 Pump stations
Supply of complimentary equipment will be provided by manufacturers with known
experience and whose products have widespread use and recognized quality on an
international level.
Control systems applicable to pipeline operation will be the subject of study by the
instrumentation discipline. Control equipment and systems specifications are outside the
scope of this document.
3.2. Air Valves and Drains
Dual purpose air valves will be used at all elevated points and at others determined in the
hydraulic transient analysis.
Air valves will be located and selected in accordance with the AWWA M51 Air Release,
Air / Vacuum & Combination Air Valves.
Piping
Rev. X
Air and drainage valve internals in contact with the fluid must be made of a material that is
suitable for withstanding the aggressiveness of said fluid.
Both air and drainage valves will be installed within a chamber for protection from freezing
and. Access to these chambers will be restricted.
For air valves located in sections of pipe working like closed conduit, the valves shall be
calculated in accordance with a Sikora expression that reasoned that the mean air velocity
could not exceed the mean water velocity. This leads to the expression for the maximum
possible airflow rate in a closed conduit, wich is:
𝑄 𝐴
1
𝑄 𝐴
Where:
Ad: cross sectional area of pipe.

A: cross sectional area of water prism.
Qa: air flow
Qw: water flow
3.3. Pipe Supports and Anchors
Aerial supports will be used in the pump stations, pig stations and valve chambers.
Stress calculations will be conducted for the design of pipe supports and anchoring blocks.
These calculations will then be provided to the Structural Discipline.
Concrete blocks will be placed at the platform access zones and next to valve chambers.
Steel materials used for the fabrication of the supports will have a tensile strength greater
than or equal to 165 MPa (24.000 psi).
A thermal stress analysis will be conducted as indicated in ASME B31.4. This analysis is
required due to temperature variations that may exist in the facilities location.
3.4. Cleaning and Inspection Stations
Pressurized metallic sections of the pipeline will include pig stations distributed along its
routing. These operations will consider a launching station wherein a scrubbing and
gauging pig may be inserted. This instrument will then be pushed along by the water flow.
The pipe will be designed to permit the uninterrupted passage of this tool to the receiving
station (“pig receiver”).
Each station will be designed according to ASME BPVC Section III Boiler and Pressure
Vessel Code.
Piping
Rev. X
Pig launchers and receivers stations will be designed to accommodate internal inspection
instruments for gauging dirt buildup and evaluating the levels of internal corrosion and
wear of the lining.
Pig launchers and receiver must have a flange connection class according to pressure level
required, a full bore API 6D shut off valve and a quick open end enclosure.
Each station will include a reception tray used for collecting the dirt eliminated from the
inside of the pipe. This tray will facilitate natural drying of the wastes or mechanical
removal thereof.
For launcher stations in gravity sections of pipeline, perforated disc butterfly valves (like
Monovar valves) shall be used to allow the pressure drop necessary for pig launching. This
ensure that the flow mainline cannot be blocked.
3.5. Pump Stations
Pump stations will be located next to water intake areas of the Vizcachas and Titire rivers.
These pump stations will include the following elements:
 Pump feed system.

 Pumps.
 Discharge header.
 Pig Launchers.
 System of distribution, recirculation, shutoff, check and safety valves.
 Surge protection system (water hammer) if applicable.
3.5.1. Water Intake
The Titire intake is a civil work that collects water from the river and conducts it to
the pumping area. The design criteria for this facility is by others.
3.5.2. Pumps
The pumps for the Vizcachas river will consist of multistage split case horizontal
pumps. Titire river pumps will consist of vertical turbine multistage pumps.
The pump materials shall be defined by the supplier based on the water quality
information obtained from study MQ09-09-RE-0000-GA0009 “Fresh water
Corrosiveness Analysis / Pipe and Lining Test Analysis” conducted by a third party
in conjunction with Anglo American.
Piping
Rev. X
The pump stations will also consider one pump on standby with the others in
operation. The number of pumps will be defined based on the type of pump, the
size of the motor and the flexibility required. A control system must be provided
that regulates the flows between sections of pipe.
3.5.3. Discharge Head
The discharge manifold will be constructed with a collector pipe and a system of
cutoff and check valves that direct the water to the main pipeline. The head will
include a recirculation system and filling system. Special attention must be given to
the design of the drainage system, considering that the pumping systems are
situated at the lower sector of the Pelluta hill.
Given the complexity of the discharge manifold design, this considers branches,
reductions, valve connections and instrumentation connections, the internal FBE
lining is therefore also complex. Given the foregoing, discharge manifold materials
will be stainless steel quality 316/316L (ASTM A312 TP316/316L).
3.5.4. Pressure Surge Protection (Water Hammer)
Elements shall have to be used for prevention or mitigation or surge phenomena, if

applicable.
3.6. Transfer Tank TAG 1140-TK-001
The tank for the transfer of water located at Pelluta hill will work like a transfer chamber.
The water tanks will be constructed of carbon steel with interior corrosion protection and a
conical roof. The design will be as indicated in AWWA D100 or API 650. The necessity of
tank insulation to avoid freezing needs to be verified by heat transfer methods.
3.7. Fresh water Transfer Tank TAG 1140-TK-002
The fresh water transfer tank, approximate location at km 3+786 (3.923,4 m.a.s.l.) of the
route of the existing construction water pipeline, will have a capacity equal to the
aforementioned charge tank and it will work like a transfer chamber too.
The water tank will be carbon steel with internal corrosion protection coating and without
roof. The design will as indicated in AWWA D100 or API 650.
Piping
Rev. X
4.0 PIPELINE DESIGN
4.1. General
The pipeline design will consider diverse aspects that require the most adequate solutions
to fresh water transport problems. Every aspect must be correctly referenced in accordance
with the appropriate codes and standards for each case. Below are the important aspects to
be considered for designing the pipeline:
 Hydraulic design
 Mechanical design codes and standards
 Route and slopes
 Pipe fittings and materials
 Possibility of fluid freeze.
 Calculation methodology
 Transient analysis (i.e. waterhammer)
 Pipe flexibility analysis
 Valve selection
 Pump stations
 Pressure dissipation stations
 Interior and exterior coating
 Cathodic protection
 Pigging
 Manufacturing process
 Draining
 Emergency system
 Use of intelligent tools (PIGS) for inspection and cleaning
 Use of robotics for interior FBE coating of welded joints.
Pipeline design must consider a minimum 92% availability.
4.2. Routes and Slopes
The design and calculations for the pipeline must match the route defined in the project
drawings. Likewise, definitions for above-ground or buried sections of pipe, changes in
Piping
Rev. X
direction or elevations of the pipeline must be in accordance with the definitions indicated
in the project drawings.
Where the electrical lines cross over the pipeline route, the distance of the towers to the
axis of the pipeline shall be no less than 11 m.
When a pipe section a run over supports, the height of these supports will be calculated
while considering the possibility of flooding over the soil surface. Therefore, a minimum
400 mm distance from the base of the pipe to the soil surface must be considered.
When the pipeline runs directly supported over the soil surface, lateral movements of the
pipe will be restricted using proper supports.
When the pipe will not be buried, the pipe bending and the distance to the high voltage
overhead lines will be the same for case of buried pipe.
A detailed trench preparation design shall be submitted by the civil discipline and must
take into consideration the soil mechanics along the pipeline route; thereby facilitating the
generation of proper slopes during the construction phase. The design must include backfill
quality and preparation of the bedding where the pipe will be placed.
4.3. Pipe Supports and Anchors
Aerial supports will be used in the areas where the pipeline runs above ground such as in
the cases of high slopes or rocky areas.
Areas where the pipeline crosses roads, railway lines and there the line surfaces above
ground will consider concrete anchor blocks to ensure restricted movement of the buried
pipe.
Stress calculations will be conducted for the design of pipe supports and anchoring blocks.
These calculations will then be provided to the Structural Discipline.
Concrete blocks will be placed at the platform access zones and next to valve chambers.
Steel materials used for the fabrication of the supports will have a tensile strength greater
there or equal to than 165 MPa (24.000 psi).
Sections of the pipeline running above ground will have supports along the entire span.
Design of these supports will consider a standard minimum yield stress (SMYS) not
exceeding 66%.
A thermal stress analysis will be conducted as indicated in ASME B31.4. This analysis is
required due to temperature variations that may exist along the route of the pipeline.
Piping
Rev. X
4.4. Hydraulic Design
Flow pressure losses in the pipe will be calculated using the Darcy-Weisbach equation and
the friction factor estimated using the Colebrook expression.
An additional 5 – 10 % must be added to the head loss value due to friction, considering the
aging of the pipe, diameter differences or any other abnormal condition of the internal
surface of the pipe. The additional head loss factor must not be added to pressure losses due
to elevation changes or acceleration. Velocities under 2.0 m/s are considered acceptable
under special conditions such as in the case of long spans of pipeline.
Another important aspect to keep in mind is the geographical variety. This allows a gravity
flow with mixed behavior (pressurized and free surface channel) and if important savings
can be obtained , this configuration may be adopted (i.e. use of HDPE runs). In summary,
the pipeline needs to be verified by head loss, pressure and velocity, taking into account the
economical factor.
For the pumped sections of pipeline, possible occurrences of waterhammer phenomena

must be carefully evaluated considering different possible operating scenarios under cases
such as power cuts or sudden closing of cutoff valves. Fluid dynamic simulation software
such as AFT Impulse will or similar will be used for such purposes. The results of this
analysis will be used to define the protection methods to employ and their relative
locations.
Parameter values and type of piping to be selected will be as indicated in Section 2.2.1. The
fabrication process data, materials, welding and linings, as offered, will be openly reported
by the manufacturer.
Drainage must be calculated considering pressure values existing at selected points and the
volumes to be drained. Each case must also consider risk control for personnel associated
with the operation of drainage devices.
Venting and combination air/vacuum valves will be designed and calculated using the
AWWA M51 manual as a reference. The position and quantity of these valves will be
defined based on the definitive route of the pipeline and must be established in the pipeline
layout drawings. These draining points will be directed towards adjacent ravines/gulleys.
Civil works will be considered at these locations to dissipate energy and to avoid
undercutting/erosion.
Hydraulic calculations of closed conduit or free surface pipeline sections must consider the
requirements indicated in points 3.3 of the Hydraulic Design Criteria document No. MQ11-
02-DC-0000-PD0002.
For sections working hydraulically like closed conduit, vents valves will be used to permit
the air feed to the interior of pipes. This valves shall be calculated for admit the air flow
according to Sikora expression indicated in equation n° 78 of United States Department of
Piping
Rev. X
Interior, Water and Power Resources Service, “Engineering Monograph N° 41 Air-Water Flow in
Hydraulic Structures”.
4.5. Mechanical Design
4.5.1. Piping and Fittings
The pipeline will be designed in accordance with ASME code B31.4 for all buried
and above ground pipe sections. The same code will be used for designing the
pump stations.
It will be understood that the design involves all integral components of the
pipeline (i.e.: pipe, fittings, flanges and separate components forming one element
by means of welding and bolting).
The mechanical design will consider all types of stress that may occur during the
pipeline’s operation; permanent stress from operation, occasional loads due to
seismic activity and transient loads due to infrequent operations such as abrupt
opening or closing of valves, starting or shutting down pumps, etc.).
Heating of the empty pipe (due to the effects of solar radiation) and subsequent
cooling thereof (due to temperature drops in the field) must be considered as a
special case, only in sections running above ground.
The design shall consider the natural movements of the pipe while in operation.
The buried portions of the pipe will have restricted movement while movement of
the sections above ground will not be restricted and will consider adequate support.
The proper elements needed for accommodating expansion and contraction of the
pipeline must be considered for its correct operation.
Fittings must comply with MSS SP75 standard for fittings from 3” up to 30”.
Directional changes for angles up to 1.5° will be made with fabricated curves on a
single pipe.
Mitered elbows are strictly prohibited.
Lateral branch connections will be furnished as indicated in section 404.3.5 of

ASME code B31.4 and must be apt for use with cleaning and inspection pigs,
where applicable.
The piping will be designed using the following mechanical calculation

parameters:
Piping
Rev. X
Thermal expansion (α): for carbon steel pipe, an thermal expansion coefficient of
11.7 x 10-6 °C-1 will be considered for temperatures up to 120° C. HDPE pipe will
consider a thermal expansion coefficient of 0.2x10-3 °C-1.
Poisson's ratio (ν): 0.3 for carbon steel and 0,46 for HDPE.
Hoop stress: SH = Pi Do / 20 t (MPa)
t = wall thickness, mm
Pi = Internal pressure, bar
Do = External diameter, mm
Maximum admissible stress must be calculated in accordance with table 403.2.1-1

of ASME code B31 for different types of metallic piping materials. HDPE piping
will consider a specified minimum yield strength of 246 kg/cm2 at 23°C, value
according ASTM D638 for PE4710 HDPE material. This value for SYMS for the
HDPE must be corrected according to the design temperature of the installation.
This value only shall be used for longitudinal stress calculations, for hoop stress in
HDPE sections, the value shall be calculated according to TR-09 of Plastic Pipe
Institute for a given SDR. For the maximum allowable value of hoop stress (design
value for safety margin), it will be considered the values tabulated in the following
table:
Table 4.1 Pressure Design for HDPE Pipes

Maximum Pressure (psi) Project Design
SDR
per TR-9 of PPI Pressure (psi)
9 255 240
11 200 185
17 130 115
21 100 85
Plastic pipes with SDR >21 are forbidden. For Plastic pipe of SDR21, it shall be
calculated for vacuum pressure collapse.
Stress analyses and mathematical modeling must be conducted by means of

Autopipe or Caesar II software for the pipeline (steeps slopes and above ground) as
well as the pump stations.
Road and railway line crossing calculations must be carried out in accordance with
API RP1102 ‘Steel Pipelines Crossing Railroads and Highways’.
Piping
Rev. X
4.5.2. General Criteria for Valves and Flanges
All valves must be ASME class for maximum operation pressure and maximum
testing pressure as indicated in ASME B16.34 and API 6D.
Specifications will be as listed in tables 423.1-1 (for materials) and 426.1-1 (for
dimensions) in ASME code B31.4. Exceptions to the foregoing must be approved
by the engineering department.
Materials that those parts of the valves in contact with the water must be made of
stainless steel class 316L or greater.
Gate valves will be selected in accordance with API 600. When these valves are
used for isolating sections of the pipeline, they must be “full port” type, however,
this is not necessary when the gate valves are used for drains.
Check valves will be selected according to API 594.
Butterfly valves will be selected as specified in API 609.
All flanges will comply with MSS SP-44 and will be the same steel grade as the
pipe.
Threaded joints shall not be permitted. All joints will be butt-welded, socket
welded or flanged.
Gaskets shall comply with ASME B16.20 (spirometallic) or ASME B16.21 (non
metallic) as required.
Machine bolts for ASME class 150 will be as specified in ASTM A307 Gr. B,
whereas the bolts will be as specified in ASTM A 194 Gr. 2H. For ASME class
300 and 600, studs will be as specified in ASTM A 193 Gr. B7 with bolts as
specified in ASTM A194 Gr.2H.
4.5.3. Piping and Fitting Materials
Metallic piping material will be API 5L, type PSL2 with longitudinal seams.
Variable thicknesses will be considered depending on the maximum pressure
values at different sections of the pipeline. The pipe will be grade X60 (minimum
yield strength of 60.000 psi) for the pumped section (between the stations an
Pelluta hill) and grade X42 for the metallic gravitational sections from the line
(from Pelluta hill to the Caracoles ponds).
Plastic components of the line will be HDPE PE4710.
Piping
Rev. X
All fittings will be fabricated with materials of the same class used for the main
pipe. All welds will be type butt-welds. The materials for metallic fittings will be
as defined in specification MSS SP-75. HDPE fittings must be the same material
used for the pipe (PE4710) and with a standard dimension ratio (SDR) that
withstands nominal pressure to the same degree as full pressure rated pipe. Elbows,
not molded, must be fabricated with a minimum of 5 miter joints.
The minimum allowable curvature for a metallic fitting use in the pipeline must be
equal or greater than 5D (given that the minimum radius to permits the passage of a
cleaning and inspection tool) and as shown in Table 4.2. The minimum allowable
curvature for fitting use in sections that will not need the passage of pig, must be at
least 1,5D.
Table 4.2.- Fitting to be used according to the Curvature Diameter

Metallic Piping
Minimum Diameter of Fitting to be Used Fabrication Standard
Curvature
1,5D Elbow MSS SP-75
Equal or greater than 5D Hot induction bending ASME B16.49
Equal to or greater than 40D Cold bending ASME B31.4
Equal to or greater than 503D
Natural bend N/A
(for API 5L X60)
Equal to or greater than 719D
Natural bend N/A
(Para API 5L X42)
Piping and fittings that are unlined on the interior and in contact with water must be
stainless steel 316L or greater.
The minimum radius of curvature for HDPE pipe will be recommended by the
manufacturer. Typically, the natural radius of curvature for HDPE pipe is as shown
in Table 4.3 below:
Table 4.3 - Plastic Pipe Curvature

SDR Minimum Radius of Curvature
21 28D
17 27D
11 27D
9 25D
According to TN-27 of Plastic Pipe Institute.
Piping
Rev. X
5.0 CONSTRUCTION
5.1. General
For sections of pipeline routed above 4.000 m.a.s.l., buried and above ground, the risk of
freezing shall be evaluated using the heat transfer rules. In those sectors without risk of
freezing, the depth will depend on the surface loads. A minimum 0,61 meter depth over the
top of the pipe will be considered for normal loads. For heavy loads that include crossings
under roads, railways etc., the minimum depth over the top of the pipe will be 1,2 m.
Furthermore, such crossings will comply with requirements set out in API 1102.
For pipe running above ground climate conditions as expressed in MQ11-02-TE-0000-

ME0001, Site Conditions will be determining factors for defining the type of external
protection to be used. External epoxy paint, with or without thermal insulations will be
defined according to risk of freezing.
5.2. Cold Bending of Pipe on Site
Procedures for cold bending metallic pipe on site will be required when the pipe must
adjust to the horizontal or vertical alignment of the pipe for the radius of curvature between
40D and 503D (for API 5L X60), and between 40D and 719D (for API 5L X42).
Care must be taken so that the diameter/thickness correlation of the pipe never exceeds 96
times. If the wall thickness reduction from bending exceeds the aforementioned value, the
resistance of the deformed wall may be lower than the minimum limit. A deformation study
will be conducted prior to any bending decisions. If bending is required, an additional
thickness will be added to the section to be bent.
The pieces to be bent will be cut from sections of pipe and will not have branch
connections nor will it be formed from 2 or more pieces with circumferential joints – even
if the joints have been approved.
Metallic pipe lined on the interior with a FBE coating must have the minimum radius of
curvature indicated in ASME code B31.4 section 404.2.2. This section specifies that the
minimum acceptable radius of curvature must not be less than 30 times the diameter of the
pipe. However, for this Project, given that the use of a robotic tool for the application of
internal FBE lining for the welded joints has a 38D limit (where 38D is equivalent to 1.5°
of the curve per diameter inch of the pipe) a minimum radius of curve of 40D has been
adopted.
5.3. Elbow or Bend Restrictions (cast or hot bent fittings) of the Line Pipe
Given the use of pigging tools on the pipeline and the restrictions for coating welded joints,
the use of bends or elbows consider the following design restrictions:
 The minimum radius of curvature of elbows to be selected must be 5D.
Piping
Rev. X
 Bends with a radius of curvature lower than 40D must be flanged in both ends.
5.4. Restrictions on Pipe located at the Installations
Given the restrictions of the application of internal FBE, all connection branches used
along the pipeline must be equal to or greater than 3”. Moreover, all spools to be installed
at the pump stations (discharge and suction manifolds) and at the reducing, vents and
drains, must be shop fabricated as a special piece with flanged ends.
5.5. Restrictions on Pipe located at High Sloping Sectors
Given the restrictions of the application of internal FBE, all pipe joints located in areas
with a slope exceeding 15% must be with welded neck flanges and must be completely
coated in the shop (from face to face on both sides of the flange).
5.6. Production Process
The pipe production process will be carried out exclusively by qualified welders with the
qualified procedure, according to API 1104. The ends to be welded will be correctly cut
and cleaned of any impurities or damage that may affect the final results.
6.0 SINGULARITIES
6.1. Drains
The discharge pipe will be calculated so that the water output velocity does not exceed 5.0
m/s in the drainage pipe and 0,6 m/s in mainline.
The drainage system shall consist of a shut-off gate valves and a group of orifice plate-
type, fluid pressure reduction disks.
Intermediary drainage points must discharge into environmentally accepted disposal

locations.
Discharge openings along the entire drainage system must always point to an open location
where there is no risk of damage to persons and/or equipment.
Pipe sections between the pump stations and the peak of Pelluta hill will drain into the
bilge to the pump stations. Pipe sections from the peak of Pelluta hill to Papujune will drain
into the Caracoles ponds or to the appropriate ravines.
7.0 INTERNAL AND EXTERNAL COATING
Pipe protection must be suitable for ensuring a minimum life of 29 years. The coating is valid
only for carbon steel pipe.
Piping
Rev. X
Internal coating of the pipe to prevent corrosion will be FBE as recommended in report MQ09-
09-RE-000-GA0009 “Analysis of Fresh water Corrosivity/Pipe and Lining Test Analysis” by
AguaMarina and defined in MQ11-02-TE-0000-PD0008 “FBE Internal Pipeline Protection
System”, based on API 5L7 “Recommended Practice for Unprimed Internal Fusion Bonded
Epoxy Coating of Line Pipe”. The thickness of the cured coating must be not less than 500
microns.
External coating of buried pipe will be coal-tar enamel, fabricated as stipulated in MQ11-02-TE-
1000-PD0007 “Coal-Tar External Pipeline Protection System” based on AWWA C203 “Coal-Tar
Protective Coatings and Linings for Steel Water Pipelines – Enamel and Tape Hot Applied”. The
thickness of the dry coating must not be less than 2,5 mm.
Buried fittings such as bends and elbows must be as indicated in section 4.5.3 of this document.
Moreover, these fittings must be externally coated with the same external protection as the pipe as
indicated in MQ11-02-TE-0000-PD0007 “Coal-Tar External Pipeline Protection System” (coal-
tar as per AWWA C203), and internally shop-coated in accordance with MQ11-02-TE-0000-
PD0008 “FBE Internal Pipeline Protection System”.
Pipe running above ground will only require an epoxy coating. The exterior coating will only be
applicable if the pipe is partially submerged in water when laying it directly over the ground.
7.1. Internal Cleaning and Inspection Systems
During operation, there is a possibility that the fresh water from the Titire or Vizcachas
may introduce a certain quantity of dirt to the pipe interior. Pig launching stations will be
used as mechanical cleaners for pressurized metallic sections of the line.
Sections of plastic pipe and / or where the flow is free surface, will not be cleaned or
inspected.
The quantity of pigging stations will be defined in accordance with the route and
characteristics of the pipeline. There will be at least 1 pigging station for each section of the
line between pump stations.
When the pipe section includes internal FBE protection, the pig design must take into
consideration such protective lining so as to avoid damaging the surface.
7.2. Corrosion Control
A - Buried pipe sections
A1 – External protection
It is mandatory for buried pipe to have a cathodic protection system (as well as a coal-
tar enamel exterior protection) which must be defined at the onset of the corrosivity
Piping
Rev. X
analysis of the soil. Corrosion control must be based on the guidelines defined in
NACE RP 0169.
The pipe must also have a system of electrical isolation to protect it from:
 Contact with other ferrous and non-ferrous elements

 The existence of high voltage transmission lines running parallel or crossing
over the pipe.
 Atmospheric electrical discharge (lightning).
 Current induced by neighboring metallic structures with cathodic protection.
The design will be in accordance with the guidelines set out in NACE SP 0177.
Cathodic protection systems will be designed by third parties – reviewed and approved
by the electrical discipline.
The existence of other protection methods on nearby metallic structures may create
electrical interference on the pipeline. Likewise, pipeline protection methods may also
create interference with these external structures. Proper isolation methods shall be
designed to avoid such interferences.
The buried pipe sections will not consider thermal insulation. These sections must be
buried at a sufficient depth to avoid freeing at the surface, as calculated by the
Berggren method.
A2 – Interior Protection
Interior pipe protection methods for buried sections are as follows:
 Interior coating (FBE)

 Periodic cleaning of the interior
Ongoing pipe cleaning will be employed to avoid accumulation of solids. The proper
system for use in this case is a pigging system.
B - Above-ground pipe sections
B1 - External protection
Above-ground sections of the pipeline are exposed to corrosive mechanical and

electrical atmospheric agents.
Above-ground pipe sections without thermal insulation and mounted on supports shall
be externally protected using a coating of liquid epoxy in accordance with AWWA
C210. Additional UV protection will be required for outer layers of the coating. The
Piping
Rev. X
base color of pipe will be painting according to MQ11-02-TE-0000-PD0010 Código de

Colores para Tuberías.
Pipe that includes thermal insulation will be protected in accordance with the
guidelines set out in NACE RP 0198. These sections must always run over supports
that isolate them from contact with soil and moisture. Moreover, they must be coated
with an anticorrosive epoxy beneath the insulation.
Cathodic protection using impressed current, combined with sacrificial anodes, will be
required on installations with piping that doesn’t have thermal insulation, where the
climate is sufficiently humid and where there is a possibility of electrical storms.
A covering placed over the insulation, made of steel or tin sheeting must be electrically
isolated (as described for pipe without insulation) using epoxy paint and the appropriate
cathodic protection. Moreover, the isolating layer must ensure an effective barrier from
rainwater or environmental moisture.
Pipe sections resting directly over the ground will not consider thermal insulation and
protection with cathodic protection by impressed current. Sacrificial anodes will be
installed if the soil resistance is abnormally high.
B2 - Internal protection
Internal corrosion control will just be as indicated for buried pipe.
A summary can be seen in Table 5.1.
C - Tanks
Tanks will be painted on the interior and exterior in accordance with MQ11-02-TE-
0000-GA0001 Especificación Técnica de Pinturas, with P6-A scheme.
The following matrix shows the protection scheme summary for pipes:
Table No. 5.1: Summary of Corrosion Control in Pipes

Interior External
External Coal- Cathodic
Pipe Assembly FBE Epoxy
Tar Protection Protection
Protection Protection
Buried Yes Yes No Yes
Above Ground Yes No Yes Yes
Piping
Rev. X
8.0 PIPING OPERATION
8.1. General
This section refers to certain aspects related to inspection, testing, start-up and maintenance
of the pipeline during commissioning and the commencement of regular operations,
including the following:
 Pipe installation
 Initial fill
 Leak detection
 Pressure tests
 Controlled draining
 Specific repairs
 Combination and vent valve operation.
Pipe installation and the aforementioned operations will be part of the technical
specification MQ11-02-TE-000-PD0006 - Fresh water Pipeline Fabrication and
Installation, and are therefore not included in this document.
END OF DOCUMENT
Piping

Anexo 25 MQ11-02-DC-1100-PD0004 - RX

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Anexo 25 MQ11-02-DC-1100-PD0004 - RX

Uploaded by

Copyright:

Available Formats

Anglo American Quellaveco S.A.

FRESH WATER PIPELINE DESIGN CRITERIA

Revision Date Originator’s Name and Reviewed/Approved by Pages

APPROVERS SIGNATURES DATE

Engineering Manager Freddie Colón gam54665

Area Manager Pablo Lattus

Project Manager Craig Lafortune

Client: José Mendivil

Issued for : Design Construction X Other VOID

FRESH WATER PIPELINE DESIGN CRITERIA

Rev. No. Date Description

A 14-Abr-2015 Issued for Internal Review

B 28-Jul-2015 Issued for Client Approval

FRESH WATER PIPELINE DESIGN CRITERIA

1.0 GENERAL ..................................................................................................................................................... 5

2.0 SYSTEM DESCRIPTION ............................................................................................................................ 9

3.0 FACILITY DESIGN ................................................................................................................................... 12

4.0 PIPELINE DESIGN .................................................................................................................................... 16

5.0 CONSTRUCTION ...................................................................................................................................... 23

FRESH WATER PIPELINE DESIGN CRITERIA

6.0 SINGULARITIES ....................................................................................................................................... 24

7.0 INTERNAL AND EXTERNAL COATING ............................................................................................. 24

8.0 PIPING OPERATION ................................................................................................................................ 28

FRESH WATER PIPELINE DESIGN CRITERIA

1.2. Codes and Standards

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

FRESH WATER PIPELINE DESIGN CRITERIA

 ASTM A307 Standard Specification for Carbon Steel Bolts, Studs,

FRESH WATER PIPELINE DESIGN CRITERIA

 API 1104 Welding of Pipeline and related Facilities.

NACE National Association of Corrosion Engineers

National Electrical Code of Peru - 2006

1.3. Design Criteria

MQ11-02-DC-0000-PD0002 Hydraulic Design Criteria.

1.4. Technical Specifications

MQ11-02-TE-0000-ME0001 Site Conditions Technical Specification.

MQ11-02-TE-0000-PD0001 Especificación Técnica Materiales de Tuberías.

MQ11-02-TE-1000-PD0006 Especificación Técnica Fabricación e Instalación

FRESH WATER PIPELINE DESIGN CRITERIA

MQ11-02-TE-0000-PD0010 Especificación Técnica Código de Colores para

MQ11-02-TE-1000-PD0007 Coal-Tar External Pipeline Protection System.

MQ11-02-TE-000-PD0008 Fusion Bonded Epoxy (FBE) Internal Pipeline

MQ11-02-TE-0000-GA0001 Especificación Técnica de Pinturas.

MQ11-02-TE-1000-PD0032 Technical Specification Pipeline Pig Launchers and

MQ11-02-DR-5400-FS1001 Infrastructure – Fresh water Treatment and Distribution –

MQ09-09-RE-000-GA0009 “Analysis of Fresh water Corrosivity/Pipe and Lining Test

1.7. AA (Anglo-American Standards)

AA-GTS-00005 AFRG5 Anglo Fatal Risk Standard – Equipment Safeguarding.

AA-GTS-00007 AFRG7 Anglo Fatal Risk Standard – Working at Heights.

AA-GTS-00008 AFRG8 Anglo Fatal Risk Standard – Lifting Operations.

FRESH WATER PIPELINE DESIGN CRITERIA

2.0 SYSTEM DESCRIPTION

A diagram of the fresh water system can be seen in Figure 2.1:

FRESH WATER PIPELINE DESIGN CRITERIA

Figure 2.1.-Pipeline Diagram

FRESH WATER PIPELINE DESIGN CRITERIA

2.2. Basis of Design

2.2.1. Titire and Vizcachas Pipelines

 Pressure Class From ASME class 150 to ASME Class

FRESH WATER PIPELINE DESIGN CRITERIA

cathodic protection system will be

3.0 FACILITY DESIGN