GERENCIA DE PROYECTOS

INGENIERÍA DE DETALLE

MEJORAMIENTO FUNDICION HORNO FLASH

POTENCIADO

DP-170013

0 marhauk 07.02.2018 tommut 07.02.2018 kritul 07.02.2018 Approved for Construction

Name Date Name Date Name Date Revision Text
Rev
Prepared Checked Released
Status: Original Size:
APPROVED FOR CONSTRUCTION A4
Customer: Project Lifecycle Phase: Site No.:
CODELCO CHILE DIV. CHUQUICAMATA IMPLEMENTATION 01 S-00262
Project Name: Customer Document ID:
CHUQUICAMATA FSF N17FP11-ID-5220-ME-SP-003
Replaced by: Replaces: Language:
EN
Document Title:
TECHNICAL SPECIFICATION
SMELTING PLANT
FLASH SMELTING
COPPER PIPING ASSEMBLY

Equipment No: Item No:

DP170013-E30-5220-ME-SP-003

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 MEC03 00012 0 1 (6)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054559
 TECHNICAL SPECIFICATION
COPPER PIPING ASSEMBLY

DP170013-E30-5220-ME-SP-003

TABLE OF CONTENTS

Table of Contents ....................................................................................................................... 2

1. General ............................................................................................................................... 2
. Codes and Standards ......................................................................................................... 3
3. Copper Pipe ........................................................................................................................ 3
4. Cu- Piping Handling ............................................................................................................ 3
4.1. Cutting of the Cu-pipe ................................................................................................ 4
4.2. Soldered Joints .......................................................................................................... 4
4.3. Joint made with fittings ............................................................................................... 5
4.4. Bending and cutting of the Cu-pipes........................................................................... 5
5. Supporting .......................................................................................................................... 5
6. Quick acting shut off valves of the tap holes ....................................................................... 5
7. Pipeline Numbering............................................................................................................. 6
7.1. Instruction for Copper Piping Tagging ........................................................................ 6
8. Pressure Testing of the Pipelines........................................................................................ 6

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 MEC03 00012 0 2 (6)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054559
 TECHNICAL SPECIFICATION
COPPER PIPING ASSEMBLY

DP170013-E30-5220-ME-SP-003

1. INTRODUCTION

This specification covers minimum requirements for design and assembly for copper
cooling piping from headers to cooling elements to be used in CHUQUICAMATA
FSF project.
This specification covers copper piping from headers to cooling elements.
Installation of the copper piping should be start after the assembly of cooling
elements, steel structures, service platforms and headers. For installation of cooling
water piping the following documents are needed:
- Cooling water system schemes/connection diagrams
- Route drawings of the cooling water piping
- Summary list of materials, piping lists
- Pipe and support type drawings

The route drawings of cooling piping give guidelines for piping assembly, space
reservation for the pipe groups and order of pipes. Navis-model is available with
copper piping models for viewing routes. OT copper piping supervisor will advise if
there rise up questions during assembly work.

2. CODES AND STANDARDS

The piping shall be designed, built and erected according to EN, ISO and DIN
standards. Cu-pipes are designed according to EN 1057 standard.

3. COPPER PIPE

Pipe type: Copper pipe EN 1057 – R220 – 28 x 1,5 – 5,5 m straight.

Pipe size: Copper Ø 28 mm x 1.5 mm (outside diameter x wall thickness)
Copper Type:
Cu-DHP
The composition shall conform to the following requirements:
Cu: min. 99,90 %, P: 0,015 – 0,040 %

4. CU- PIPING HANDLING

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 MEC03 00012 0 3 (6)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054559
 TECHNICAL SPECIFICATION
COPPER PIPING ASSEMBLY

DP170013-E30-5220-ME-SP-003

Special attention must be given when handling the Cu-pipes because pipes are
annealed and softer than steel pipes.
Connections of the Cu-pipes have to be checked according to the cooling system
schemes.
Before connecting the Cu-pipes to the cooling element, each line shall be blasted
with compressed air.
The same assembly group shall install the Cu-pipes of each header from the
beginning to the end.

4.1. Cutting of the Cu-pipe

Cu-pipes are cut to the correct lengths with either cutting device of the Cu-pipe or
with narrow cut disk.
Cutting must be done as straight as possible.
After cutting the burrs are removed with the cutter of the Cu-pipe.

4.2. Soldered Joints

Following tools and equipment are used to carry out of the work for soldered joints:
- Tables equipped with filing vices
- Gas Welding/Soldering equipment, have to be suitable for cu-soldering (600 C
– 750 C).
- File and grinding paper
- Cutting tools of the Cu-pipes and hacksaw or narrow cut disk
- Soldering wire Cu 80%, Ag 15%, P 5 %
- Soldering paste or powder
- Water for cooling and cleaning
- Tool for enlarging the pipe ends

Procedure of soldering:
1. The pipes are bent and cut to the correct lengths
2. Ends of the pipes are straightened
3. Burrs are removed
4. Other end of the joint shall be enlarged by special tool from the length of about
15-20 mm.
5. Both parts of the soldered seam are cleaned with abrasive paper and free of any
contamination
6. Cu-pipe is pushed into the socket or into end of the enlarged pipe. Parts which
will be soldered together have to be on the same line.
7. Joint is heated to the soldering temperature, approx. 600 C – 750 C.

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 MEC03 00012 0 4 (6)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054559
 TECHNICAL SPECIFICATION
COPPER PIPING ASSEMBLY

DP170013-E30-5220-ME-SP-003

8. The soldering wire is added to the heated seam. Soldering paste or powder is
used only when soldering Cu-pipe to the brass union fittings of the tap hole
cooling elements, cooling water headers and others.
9. Remains of the soldering paste are removed by cooling the hot joint with water
and after that by wiping remains off with cloth.

Notice! The whole capillary seam must be filled with soldering material.

Soldering wire (Cu 80 %, Aq 15 %, P 5 %), according to DIN standard 8513, L-Ag

15 P / EN 1044: CP102, or equal. Diameter of the wire is 2 mm or 3 mm.
Each seam needs maximum 5 g (normally 1.5 g) of soldering material.

4.3. Joint made with fittings

Pipe sealant, pipe tape or plumber’s hemp and paste will be used in threaded joints.
Locktite 577 or equivalent is the most favourable in this application.

4.4. Bending and cutting of the Cu-pipes

The bending tool must be used when bending the annealed Cu-pipes. Electrical or
hydraulic bending tool is the most recommended.
Minimum radius of bended pipe shall be four times the pipe outside diameter, i.e. 4
x 28 mm = 112 mm. Recommended radius 5 x 28mm = 140 mm. Maximum allowed
flattening of the pipe after bending is 5 %.
Pipe cutting device must be used when cutting the Copper pipes. Cutting must be
done as straight as possible. After cutting the burrs are removed with the cutter.

5. SUPPORTING

Maximum distance between supports is about 2.5 m, when supported pipes are in
horizontal level.
Types of anchor and slide supports as well as location of the primary supports are
shown by piping route drawings. Typical drawings include pipe supporting
instructions.

6. QUICK ACTING SHUT OFF VALVES OF THE TAP HOLES

Quick acting shut off ball valves will be installed by brass union fittings in the supply
water lines of the cooling elements of matte- and slag tap holes.
Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 MEC03 00012 0 5 (6)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054559
 TECHNICAL SPECIFICATION
COPPER PIPING ASSEMBLY

DP170013-E30-5220-ME-SP-003

7. PIPELINE NUMBERING
Circuit numbers of all pipes are given in the cooling system schemes
302205_PSP01_PS01_PFB01_18000…18008.
The cut pipes have to be tagged with the circuit numbers. After installation, the Cu-
pipes must be furnished with number plate, made of corrosion resistant material and
fixed with Cu-wire to pipe, just above the diaphragm valves of headers and to the
inlet and outlet pipes of cooling elements.

7.1. Instruction for Copper Piping Tagging

Each copper supply line and return line shall be labelled with stainless steel
stamped/engraved plates to both pipe endings. C-pipes (series connections) shall
be labelled with one plate per pipeline.
Plates will be hung up just above valves of headers and to the inlet and outlet pipes
of cooling elements by using Cu-wire according to drawing
302205_PSP01_PS01_MED08_00004.
Copper wire diameter 1.0 mm, material CW004A E-Cu58 or equivalent. Copper wire
length 300 mm per plate.
Tag numbers are listed in a separate list.
Plates will be packed separately as per header
Plate dimensions are according to drawing 302205_PSP01_PS01_MED08_00005.

8. PRESSURE TESTING OF THE PIPELINES

After installation the pipelines shall be cleaned and pressure tested with air.
Step 1: Cleaning inside of the pipe use compressed air.
Step 2: In performing step 1. also confirm the inlet and outlet of the pipe are correct
(they must be on same vertical line on header). All pipe circuits shall be tested.
Step 3: Pressure test pipe with pressurized air, test pressure is 3-5 bar and
minimum testing time per line 10 min. All joints of every circuit must be checked with
water mixed soap solution. Use of pressurized air is recommended as in case of
leakage water may enter to the brick lining of the furnace. If testing fluid is water,
final test pressure has to be 8 bar.
For cooling water circuit testing is available separate testing specification
302205_PSP01_PS01_MEC03_00013 - Technical specification for SENTINEL AND
COPPER PIPING CIRCUITS TESTING.

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:

302205 PSP01 PS01 MEC03 00012 0 6 (6)

The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Reproduction, Outotec Document ID:
transfer or distribution of part or all of the contents in any form without the prior written permission of Outotec is prohibited.
OU100054559