FABRICATION & INSTALLATION PROCEDURE

1.0 General Arrangements on site

Astaldi-CBI prepared an area for the penstock fabrication, quality control, sand
blasting and painting shops. These facilities are located in the Unduavi Valley, in a
suitable area in Sacahuaya close to the Yanacachi Penstock and Powerhouse. Nearby a
camp facilities are also constructed for personnel working in the Penstock
Manufacture and Erection activities.

A factory supervisor with a staff of 40 to 50 workers (according to work progress) are

employed for pipe fabrication activities and an erection supervisor with a staff of
20 to 40 workers pipeline (according to work progress) are employed for the
erection and testing of the Penstock. Welders and other personnel which have
already worked with Astaldi-CBI in other similar jobs (Zongo and San Jacinto ) are
employed as far as possible, there will be 2 qualified Inspectors, 1 for the manufacturing
process and 1 for the erection process. Welders and inspectors will be trained and
certified by approved welding experts, and according to the attached
"Qualification Procedures for Welders”.

Nondestructive tests will be carried out by Astaldi-CBI's inspectors under the

supervision of a welding expert who will issue Quality Control Reports and
Certificates of Tests that have been carried out during fabrication.

2.0 Site plan & equipment

Site Plan Attached

TAQUESI PROJECT PENSTOCK MANUFACTURING SHOP FACILITIES.

No. 1 1000 Square Meters of the main body structure in steel with steel roof,
steel side walls and gates, for Penstock Manufacturing Shop;
No. 1 200 square Meters of the main body structure in steel with steel roof,
steel side walls and gates, for sand Blast and Painting activities;
No. 2 5 Tons Overhead Traveling Bridge Crane - lifting capacity six
(6) meters from bottom.
No. 1 12 Tons Caterpillar V300B Fork Lift with Diesel Motor;
No. 1 Diesel Generating Set, 150KW;
No. 1 Steel Plates Guillotine Shear - Capacity 25 x 3000 Millimeters;
 No. 4 Oxyacetylene Single or Multi Torch with motorized Cutting Machine for
cutting and beveling of Steel Plates.
No. 1 Three Roller Bending Machine with 16 x 2550 millimeters Capacity -
minimum radius of 200 millimeters
No. 1 Three Roller Bending Machine with 45 x 3000 millimeters Capacity -
minimum radius of 500 millimeters
No. 4 Motorized adjustable Pipe Rollers Capacity of six (6) Ton load with twelve
(12) Tons Rotation.
No. 15 Free adjustable Pipe Rollers. Capacity of six (6) Tons Load
No. 1 Automatic Submerged Arc welding Machine ESAB Type, mounted over
motorized manipulator with DC Generator of 800 Amps. The
Manipulator has arm four (4) meters long and three (3)
meters supporting column plus the standing platform. The motorized systems
moves over rails and have the possibility to weld longitudinal and
circumferential joints inside and outside of the pipes.
No. 3 Submerged ESAB and Lincoln Tractor type with 800 and 600 Amps DC
Generators. The Tractors over special guides has the
possibility to weld longitudinal and circumferential outside and inside joints
in a fixed position, with pipe over Motorized Tube Rollers. (Normally
the circumferential inside joints would be welded with a
manipulator)
No.14 ESAB DC 400 Amps Welding Machine for manual welding.
No.2 ESAB DC 600 Amps Welding Machine for manual welding and for Arc Air
Torch.
No. 1 ESAB DC 400 Amps Gas Semi-Automatic Welding Machine
No. 3 High Frequency Generator with four (4) Inlets each for Grinding Machines
No. 8 High Frequency Angular Grinding Machine
No. 1 Directional x-ray Apparatus - 200 kW for Quality Control
No. 1 Ultrasonic Apparatus for Quality Control
No. 1 Alternative Motorized Saw
No. 2 Heating and Treatment Ovens for Submerged Arc Welding Flux
Electrical Type
No. 2 Vertical Heating and Treatment Ovens for Welding electrodes Electrical
Type - Around 1200 Electrodes capacity
No. 2 Electrical Motorized Air Compressors for Arc Air Torches
No. 1 Diesel Motor Welding Machine - 600 Amps
No. 2 Pick-up or Shop service.

The shop is complete with all the electrical and distribution panels, lighting system, air
distribution system and all necessary hand tools such as hydraulic and mechanical jacks,
tir-4, lift pulleys, lifting cables, individual tools and all the protective clothing required.
Also incorporated in the shop will be tools spare parts and consumable materials
store. Store for welding materials, first aid infirmary, workshop office, x-ray laboratory
and permanent material store.

For the Taquesi project the shop will also be provided with the
following:

No. 1 Air Compressor of High Capacity - 7 Bars,

No. 2 Sand Blasting Machines,
No. 1 Infrastructure to meet environment basic requirements.
No. 2 Cable way (Blondins) load capacity 5 Tons.

3.0 Manufacturing / Fabrication Process Specifications

Fabrication shall comply with ASTM, AWWS, AWS standards and

specifications. Nondestructive testing will be 100% ultrasonic testing, and 15% for pipe
factory and 60% pipeline radiographic examinations of circumferential and longitudinal
joints. Depending on the performance of the welders and radiographic examination
records, the percentage requirement of radiographic examination can be reduced.

The manufacturing process will be as follows:

 Check drawings, QA handbook and welder certificates;
 Receiving material and Certificates test Result from Mill;
 Marking plates;
 Squaring, cutting plates with guillotine shear or oxyacetylene;
 Beveling and special cuttings with oxyacetylene;
 Roll bending with machine for plate 8/30 mm thick. Use jig to control radius;
 Longitudinal tack welding;
 Longitudinal internal/external submerged arc welding;
 Assembling of pipes;
 Circumferential internal submerged arc welding;
 Circumferential external submerged arc welding;
 Check dimensions and roundness (Sample sheet is attached);
 Visual dimensions check and perform NDE;
 Repairs of faulty elements;
 Perform NDE of repaired elements;
 Pipe welding sheet will be prepared (Sample sheet is attached);
 Sandblasting;
 Painting;
 Painting inspection;
 Each pipe will be marked with an ID and Position number.
3.1 Construction characteristics

Materials:
The steel utilized for manufacturing the Penstock is ASTM A537 CL. 1 - produced
in Italy and all other welding materials according to WPS (Welding Procedure
Specifications).

Material characteristics
a. The metal plates for the manufacturing the Penstock shall be ASTM A537 CL. 1 -
produced in Italy shall be produced in compliance with applicable
specifications;
b. All welding materials shall be in compliance with WPS and applicable
specifications;
c. The steel used in the construction of the other parts such as Bends, Manifolds,
Flanges and Expansion Joints shall also be ASTM A537 CL. 1;
d. Anchor rings for pipes AP11AP17 will be manufactured and welded to the
pipes in the shop;
e. Manholes will be placed according to shop drawings and will be manufactured in
the shop;
f. Expansion joints will be manufactured in the shop. Assembling of expansion
joints will be made accordance with specifications, pipes will be cut
according to a thermal expansion charts, depending on the temperature and
length in which the expansion joint is installed;
1. Saddle supports steel plate, 8 mm thick, shall have a half moon of 120º
form, and shall be welded to anchor hooks for second stage concrete;
2. Pipes shall be completely painted in the shop, except for 20 cm. at both
ends that shall be painted on the job site, after erection and inspections.
g. The flange and coupling – tie rod, bolt and nut dimension after machining shall not
be inferior to nominal values.
h. The average internal diameter of every pipe or element, established by the
measure of the external development at the two ends and of the thickness, shall
not be different from the theoretic diameter more than 0.3% plus or minus with
a maximum of 5 mm.
i. The ovalization of every pipe or segment, determined by the maximum length
difference of almost two diameters perpendicular between them, cannot be
greater than 0.01D, D been the theoretic internal diameter.
j. Anchor rings shall be fabricated and welded to the pipes in the workshop
according to approved shop drawings.
k. Mechanical expansion joints shall be manufactured in the workshop according
to approved shop drawings.
 l. The theoretic mass of every pipe or element appear on the single mass list an
the shop drawings on the basis of the final project for the piping, a variation less
than 5% is accepted. The theoretic mass shall be calculated on the basis of the
nominal dimensions and mass volume of 7.85 kg/dm³

3.2 Welding
Materials used in the construction of welded parts shall comply with the requirements
for materials given and shall be proven of weldable quality.

a. Records of the names of the welders who make each weld shall be maintained.
Welders and welding operators shall be qualified and qualification records
shall be available for audit.
b. Two sample tests will made, for tensile test and for bend test as per attached
sheet. These tests will be certified by a qualified firm.
c. Welding of the pipes in the workshop will be by automatic welding machines.
Welds will be butt welds from inside and outside. In tunnel sections welding will
be from inside only against external counter bars.
d. The edge to be butt welded shall be completely free from exfoliation, cracks or
incision, rust, calamine, humidity and shall be, therefore, submitted to the checks
and adequately protected.
e. When the temperature of the elements to be welded is lower than +5°C, and
anyhow when the room temperature is lower than –5°C or there is excessive
ventilation (with influence on the protection of the arc), the welding operations
shall be made with appropriate methods so that the cooling, after the welding,
is sufficiently slow to guarantee from cracking risk.
f. The removal of alignment jacks, tack welds and/or other possible appendixes
shall be done by grinding and subsequent visual examination of the grinded areas .

4.0 Tests, inspection, assembling and installation

4.1 Generality
For planning and checking of the construction phases (manufacturing), for assembling
(erection) and put in service (starting), the formulation related to the tests and control
and for certified documentation, are valid with the following specification.

a) For site activity, welding sheets shall be used;

b) Certified documentation relating to tests and checks will be related with the single
check and test carried out and will state the checked values and their
evaluation, the used method, the referring standards or the procedure used.
5.0 Erection and installation process specification

The procedure for Penstock installation on job site is as follows:

 The pipes will be transported from the pipe factory to the erection site on a
truck with special supporting saddles;
 Set up equipment, tools, temporary support shall be ready on the erection site
including ventilation for the steel lined sections;
 Pipes will be unloaded with a cable way (Blondins) Lifting Capacity 5 Tons;
 When working on slope and elevation areas, internal and external scaffold will be
prepared and erected.
 The pipes will be lifted brought to position with the Blondins, a 60 cm alignment
slide will be welded and the joint spaced with a 2- 3 mm spacer ;
 If necessary an aux. support will be welded on the front part to maintain the pipe
in position;
 The pipe will be aligned and edges tack welded;
 The inside welding shall be carried out first;
 The exterior will be cleaned with arc-air and welded from the exterior;
 Ultrasonic and radiographic tests will be made and eventual repairs will be carried-
out;
 The welded part will be painted and the painting will be checked;
 Anchor rings for pipes AP11AP17 will be manufactured and welded to the pipes
in the shop.
 Manholes will be placed according to approved shop drawings and will be
manufactured in the shop.
 Expansion joints will be manufactured in the shop. Assembling of expansion
joints will be made in accordance with specifications. Slip pipes will be cut
according to a thermal expansion charts, depending on the temperature and
length in which the expansion joint is installed ;
 Saddle supports steel plate, 8 mm thick, shall have a half moon of 120  form, and
shall be welded to anchor stay hooks.
 Welding will proceed in accordance with WPS here after specified. For security
reasons during night shifts, the interior of pipe will be welded and during day shifts
the exterior will be welded;
 Painting and controls will follow;
 For erection of steel lined tunnel sections, a trolley mounted on rails will be used
to transport the pipes, auxiliary foot supports welded to the pipe ends will be left
to concrete. Welding will befrom inside only against external counter bars ;
 Visual inspection will be carried-out in the interior of the piping;
 Covers of the manholes will be placed, o-rings checked;
 Expansion joints will be tightened to torque;
 Finally the piping will be filled with water and leak tested ;
  Infiltration and leak inspections and controls will be carried-out;
 A hydropressure test will be carried out to underground piping prior to
covering. Hollow blind flanges with adequate safety valves and manometers will
be welded at the 2 ends of the piping. The piping will be filled with water;
pressure will be gradually brought to 1-1/2 times the design pressure of the
piping and maintained for 30 minutes; after a visual control of the piping the
pressure will be lowered to the design pressure and maintained at this pressure
for the time required to permit inspection of the piping. If during test defects
appear, the defectous element will be repaired in accordance to specifications
and the hydrostatic test will be repeated. The blind flanges will be removed, and
the erection will proceed.

WELDING PROCEDURE

1.0 Cutting, Fitting and Alignment

a. When plates are shaped by oxyacetylene or arc cutting, the edges to be welded
shall be uniform and smooth and shall be freed of all loose scale and slag
accumulations before welding.
b. Plates that are being welded shall be fitted, aligned, and retained in position
during the welding operation.
c. Bars, jacks, clamps, tack welds, or other appropriate means may be used to hold
the edges of parts in alignment. Tack welds used to secure alignment shall either
be removed completely when they have served their purpose, or their stopping
and starting ends shall be properly prepared by grinding or outer suitable
means so that they may be satisfactorily incorporated into the final weld. Tack
welds, whether removed or left its place, shall be made using a fillet weld or butt
weld procedure qualified in accordance with Section IX. Tack welds to be left in
place shall be made by welders qualified in accordance wills Section IX, and
shall be examined visually for defects, and if found to be defective shall be
removed.
d. The edges of butt joints shall be held during welding so that the tolerances are not
exceeded in the completed joint. When fitted girth joints have deviations
exceeding the permitted tolerances, the head or shell ring, whichever is out-
of-true, shall be reformed until the errors are within the limits specified.
Where fillet welds are used, the lapped plates shall fit closely and be kept in
contact during welding.
2.0 Cleaning of surfaces
Cleaning of surfaces to be welded
a. The surfaces to be welded shall be clean and free of scale, rust, oil, grease, slag,
detrimental oxides, and other deleterious foreign material. The method and
extent of cleaning should be determined based on the material to be welded
and the contaminants to be removed. When weld metal is to be deposited over a
previously welded surface, all slag shall be removed by a roughing tool,
chisel, chipping hammer or other suitable means, as to prevent inclusion of
impurities in the weld metal.
b. Cast surfaces to be welded shall be machined chipped, or ground to remove
foundry scale and to expose sound metal.
c. The requirements in (a) and (b) above are not intended to apply to any process of
welding by which proper fusion and penetration are otherwise obtained and by
which the weld remains free from defects.

2.1 Preparation of base metal

The edges or surfaces of the pieces to be joined by welding shall be prepared by flame
cutting, plasma arc cutting, arc gouging, machining, shearing, grinding, or chipping and
shall be cleaned of detrimental oil, grease, scale and rust. The edges of the pieces may
have a protective coating applied to them which need not be removed before they are
welded unless specifically prohibited by the specific WPS.

3.0 Welding process specification

3.1 General welding procedure specifications for shielded metal arc process

Scope
This is a general Welding Procedure Specification to be used with a specific
Welding Procedure Specification (WPS) when referred on the WPS. In case of
conflict between these documents and the specific WPS, the specific WPS shall
govern.

Reference
ASME Boiler and Pressure Vessel Code, Section IX. Welding Qualifications, Edition
and Addenda as shown on the specific WPS. Procedure qualifications WPS for the
project have been supplied by the welding materials supplier ESAB.
4.4 General welding procedure specifications for submerged arc welding
process (SAW)

Scope
This is a general Welding Procedure Specification to be used with a specific
Welding Procedure Specification (WPS) when referenced on the WPS. In cases
of conflict between this document and the specific WPS, the specific WPS shall
govern.

Reference
ASME Boiler and Pressure Vessel Code, Section IX, Welding Qualifications, Edition
and Addenda as shown on the specific WPS. Procedure qualifications WPS for the
project have been supplied by the welding materials supplier ESAB.