ts12 technical specification - piping

5/28/2018 Ts12 Technical Specification - Piping

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Revision Issue Date Issue Purpose Prepared By Approved By

7 07-02-13 Project Specific 300010 Santa Elena SS SD6 6-Apr-10 Minor update PMS 12 Bolting: Stud & Nuts Standard LK PDS5 18-Feb-10 Add Piping Material Specifications 11 and 12 PP RDS4 15-Feb-08 Minor corrections to Piping Material Specifications 4, 6, 7, 10 PP RDS3 17-Oct-07 Minor corrections and update to V7 Check Valves MS PP2 23-Jul-07 Issued for construction PP RDS1 21-Jun-07 Issued for construction PP RDS0 8-Mar-07 Issued for construction PP RDS

TECHNICAL SPECIFICATION

TS-12

PipingSANTA ELENA - MEXICO


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TECHNICAL SPECIFICATIONPIPING

TS-12

TS-12 07-Feb-13 Page 2 of 58Revision 6

TABLE OF CONTENTS

1. SCOPE ................................................................................................................................................ 42. REFERENCE CODES AND STANDARDS ........................................................................................ 43. ABBREVIATIONS............................................................................................................................... 64. RELATED DOCUMENTS ................................................................................................................... 75. DESIGN DETAILS .............................................................................................................................. 75.1 Pipework ............................................................................................................................................ 75.2 Flanges ............................................................................................................................................... 85.3 Fittings ............................................................................................................................................... 85.4 Paint ing and Service Identi fication ................................................................................................. 95.5 Line Numbering ............................................................................................................................... 125.6 Nominal Pipe Sizes ......................................................................................................................... 125.7 Piping Material Speci ficat ion ......................................................................................................... 145.8 Valves ............................................................................................................................................... 146. PIPING SPECIFICATION DATA SHEETS ....................................................................................... 17

Piping Material Specification 1 .......................................................................................................... 18Piping Material Specification 2 .......................................................................................................... 20Piping Material Specification 3 .......................................................................................................... 22Piping Material Specification 4 .......................................................................................................... 25Piping Material Specification 5 .......................................................................................................... 27Piping Material Specification 6 .......................................................................................................... 29Piping Material Specification 7 .......................................................................................................... 31Piping Material Specification 8 .......................................................................................................... 34Piping Material Specification 9 .......................................................................................................... 36Piping Material Specification 10 ........................................................................................................ 37Piping Material Specification 11 ........................................................................................................ 39Piping Material Specification 12 ........................................................................................................ 41

7. FABRICATION / MANUFACTURE .................................................................................................. 437.1 General ............................................................................................................................................. 437.2 Shop Fabricat ion ............................................................................................................................. 437.3 Weld ing ............................................................................................................................................ 447.4 Inspection and Testing ................................................................................................................... 468. INSTALLATION, ERECTION AND CONSTRUCTION (SITE WORKS) .......................................... 488.1 General Requi rements .................................................................................................................... 488.2 Cleanliness and Protection ............................................................................................................ 488.3 Installation of Valves....................................................................................................................... 498.4 Piping for Rotat ing Equipment ...................................................................................................... 498.5 Flanged Joints and Bolt ing ............................................................................................................ 50


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8.6 Pipe Suppor ts .................................................................................................................................. 508.7 Insulated Pip ing ............................................................................................................................... 518.8 Stainless Steel Piping ..................................................................................................................... 538.9 Plasti c Pip ing ................................................................................................................................... 538.10 Rubber Lining .................................................................................................................................. 538.11 Polyurethane Lin ing ........................................................................................................................ 548.12 Galvanised Piping ........................................................................................................................... 548.13 Min ing Hose ..................................................................................................................................... 548.14 Under Ground Piping ...................................................................................................................... 549. COMMISSIONING AND TESTING ................................................................................................... 569.1 Pressure Testing ............................................................................................................................. 569.2 Cleaning and Reinstatement .......................................................................................................... 58


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1. SCOPE

This specification defines the materials of construction, connection types and protective coatingsrequired for piping components and valves for use in the construction of process and servicespiping systems. It also defines the requirements for fabrication and installation of piping systemcomponents.

Where conflict between this specification and issued for construction drawings exists, theinformation provided on issued for construction P&IDs and piping drawings shall take precedenceover this specification. Any instance of conflict between issued for construction drawings and thisspecification must be reported immediately to the company representative.

2. REFERENCE CODES AND STANDARDS

The works and coatings to which this specification refers shall conform to all the appropriate

Australian Standards and where not covered by these, to the appropriate British Standards.

All materials and workmanship shall comply with the requirements of the following Standards.

AS 1111 ISO Metric Hexagon Bolts and Screws Product Grade C Bolts

AS 1112 ISO Metric Hexagon Nuts Style 1 Product Grade A and B

AS 1345 Identification of the Content of Pipes, Conduits and Ducts

AS 1444 Wrought Alloy Steels

AS 1477 PVC Pipes and Fittings for Pressure Applications

AS 1594 Hot-Rolled Steel Flat Products

AS 1657 Installation and Maintenance of Steel Pipe Systems for Gas

AS 1722 Pipe Threads of Whitworth Form, Part 1 Sealing Pipe Threads (based onISO 7)

AS 2129 Flanges for Pipes, Valves and Fittings

AS 2528 Bolts, Stud Bolts and Nuts for Flanges and Other High and Low TemperatureApplications

AS 3500 Plumbing Code of Australia

AS 4041 Pressure Piping

AS 4130 Polyethylene (PE) Pipes for Pressure Applications

AS 4131 Polyethylene (PE) compounds for pressure pipes and fittings

BS 6374 Part 5: Lining of Equipment with Polymeric Materials for the ProcessIndustries (Rubber Lining)

BS 6755 Testing of Valves

API 5L Line Pipe

ASTM A53 Pipe, Steel, Black and Hot Dipped, Zinc Coated, Welded and Seamless

ASTM A105 Forgings, Carbon Steel for Piping Components

ASTM A181 Carbon Steel Forgings for General Purpose Pipe

ASTM A182 Forged or Rolled Alloy Steel Pipe Flanges, Forged Fittings and Valves and

Parts for High Temperature ServiceASTM A193 Alloy Steel and Stainless Steel Bolting. Materials for High Temperature

Services


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ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High Pressure and HighTemperature Services

ASTM A216 Steel Castings, Carbon, Suitable for Fusion Welding for High TemperatureServices

ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate andElevated Temperatures

ASTM A312 Seamless and Welded Austenitic Stainless Steel Pipe

ASTM A403 Wrought Austenitic Stainless Steel Piping Fittings

ASTM A536 Ductile Castings

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory-Made Wrought Steel Butt Welding Fittings

ASME B16.11 Forged Steel Fittings, Socket Welding and Threaded

ASME B16.25 Butt Welding Ends

ASME B31.3 Process Piping

ASME B36.10 Welded and Seamless Wrought Steel Pipe

ASME B36.19 Stainless Steel Pipe

ANSI B2.1 American Standard Taper Pipe Thread, NPT

ANSI/ASME B16.5 Steel Pipe Flanges and Flanged Fittings

ANSI/ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings

ANSI/ASME B16.10 Face-to-Face and End-to-End Dimensions of Ferrous Valves

ANSI/ASME B16.11 Forged Steel Fittings, Socket Welding and Threaded

ANSI/ASME B16.20 Ring Joint Gaskets and Grooves for Steel Pipe Flanges

ANSI/ASME B16.21 Non-metallic Gaskets for Pipe Flanges

ANSI/AMSE B16.25 Butt Welding Ends

ANSI/ASME B16.28 Wrought Steel Butt Welding Short Radius Elbows and Returns

ISO 7-1 Pipe Threads where Pressure Tight Joints are Made on the Threads. Part 1:Dimensions, tolerances and designation

DIN 8077 Pipes of Polypropylene (PP) Dimensions

BS 6374 Pipes of Polypropylene (PP) General Quality Requirements

ASTM D2239 Standard Specification for Polyethylene (PE) Plastic Pipe (S.D.D.R-PR)Based on Controlled Inside Diameter

ASTM D2737 Standard Specification for Polyethylene (PE) plastic tubing

ASTM D3035 Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based onControlled Outside Diameter.

ASTM F714 Standard Specification for Polyethylene (PE) Plastic Pipe (S.D.D.R-PR)Based on Outside Diameter


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3. ABBREVIATIONS

ANSI American National Standards InstituteAPI American Petroleum Institute

AS Australian Standards

ASME American Society of Mechanical Engineers

ASTM American Society of Testing and Materials

BE Bevel End

BS British Standard

BSP British Standard Pipe Thread

BW Butt Weld

CS Carbon Steel

DN Nominal Diameter (Number)

EFW Electro Fusion Welded

EPDM Ethylene Propylene Diene Modified

ERW Electric Resistance Welded

FCAW Flux Core Arc Welding

FF Flat Face or Flange Face

GR Grade

GRES GR Engineering Services LimitedGTAW Gas Tungsten Arc Welding

HDPE High Density Polyethylene

ID Inside Diameter (number)

ISO International Standards Organisation

LR Long Radius

MMA Manual Metal Arc

NB Nominal Bore (Number)

NPS Nominal Pipe Size (Number)

OD Outside Diameter (Number)

P&ID Piping and Instrumentation Diagram

PE Polyethylene

PN Nominal Pressure (Number)

PP Polypropylene

PTFE Polytetrafluoroethylene (Teflon)

RF Raised Face

Sch Schedule

SMLS Seamless

SO Slip On


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SS Stainless Steel

Std Wt Standard Weight

TIG Tungsten Inert Gas

UNS Unified Numbering System for Metals and Alloys

WN Weld Neck

4. RELATED DOCUMENTS

Technical Specifications related to this document are:

TS15 Surface Treatment.

This document is linked to the following GRES Standard Drawings:

Piping and Instrumentation Symbols.

Small Pipe 'Site Run' Supports.

Piping Details.

Instrumentation Details.

Valve Identification.

Typical Rubber Lining Details.

Warman Pump Matching Flange Details.

5. DESIGN DETAILS

5.1 Pipework

All materials, design and fabrication for pipes, fittings, valves and ancil lary items for pressure pipingsystems shall be in accordance with ASME B36.10 and this specification unless noted otherwisestated on the drawings.

Pipes shall be supplied in accordance with ASTM A53 Gr B, API 5L Gr B or ASTM A106 Gr B.

Material specifications shall be in accordance with the AS, ASTM or API standards specified foreach Piping Class.

For the purpose of this specification, pressure is measured in kPa.g (kilopascal gauge).

All piping component wall thicknesses specified for the individual Piping Classes are in accordancewith AMSE B36.10 and the wall thickness calculations shall be based on the internal designpressure, design temperature, corrosion allowance and the manufacturers tolerance. Steel piping,if specified, to ASME 31.3 (Normal)

Metallic pipe, valves and fittings sized DN 32, 65, 90 and 125 shall not be used. Where equipmentis specified with connections of the sizes listed above, connections shall be made with suitableswages or reducers to suit a pipe of an approved size.

Polyethylene Pipe shall be in accordance with ASTM D2837, D3350 for PE 4710 grade.

Nominal Pipe sizes is used for sizing of Poly pipe in the USA instead of the OD, hence Iron PipeSize (I.P.S) is to be used for pipe numbering. (I.P.S = Nominal Bore (NB)).


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Metallic pipe sizes (Nominal Diameter) and wall thickness shall be specified in millimetres and shallbe in accordance with ANSI/ASME B36.10 or B36.19.

All buried metallic piping shall be externally protected with either yellow jacket or Denso wrap.

Preferred branch connection arrangements are given in the branch connection table for eachindividual piping specification. Reducing tees are a preferred branch connection. Where pipe topipe branch connections are used, the reinforcement requirement shall be provided in accordancewith ANSI/ASME B31.3. Branches shall not be located on removable spools or elbows.

Hot service pipes, fittings, flanges and valves shall be insulated for personal protection or thermalefficiency in accordance with the specification nominated in the supply contract document.

All pipe nipples shall be 4 long, unless specified otherwise.

5.2 Flanges

Flanges shall be to American Standards ASME B16.5 unless otherwise noted on design drawings.Flanges shall be minimum PN20 (ANSI 150).

For Polyethylene Pipes ANSI 150 will be required unless otherwise stated on the drawings

For Carbon Steel Pipe ANSI 150 will be required unless otherwise stated on the drawings.

5.3 Fittings

Butt welded, flanged and threaded fittings shall be in accordance with ANSI/ASME B16.9, B16.5and B16.25 respectively. Threads shall be NPT

NPT - American Standard Pipe Thread Taper1)

Pipe Size(inches)

Threads perInch

TPI - pitch

Approximate Length of

Thread(inches)

Approximate Numberof Threadsto be Cut

ApproximateTotal thread

Makeup,Hand andWrench(inches)

NominalOutside Pipe

DiameterOD

(inches)

Tap Drill(inches)

2" 11-1/2 1 11 5/8 2.375 2-7/32

2-1/2" 8 1 1/2 12 7/8 2.875 2-5/8

3" 8 1 1/2 12 1 3.500 3-1/4

3-1/2" 8 1 5/8 13 1 1/16 4.000 3-3/44" 8 1 5/8 13 1 1/16 4.500 4-1/4

4 1/2" 8 5.000 4-3/4

5" 8 1 3/4 14 1 3/16 5.563 5-9/32

6" 8 1 3/4 14 1 3/16 6.625 6-11/32

8" 8 1 7/8 15 1 5/16 8.625

10" 8 2 16 1 1/2 10.750

12" 8 2 1/8 17 1 5/8 12.750

14" 8 14.000

16" 8 16.000


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5.4 Painting and Service Identification

5.4.1 Piping to be CoatedOn completion of fabrication and prior to installation, piping spools shall be surface protected inaccordance with GRES Specification for Surface Protection, except as follows:

Plastic (ABS, GRP, UPVC) piping shall not be coated.

Stainless steel (any grade) shall not be coated except where specified on the designdrawings.

Insulated carbon steel piping shall be prime coated only prior to installation of insulation.

Galvanised piping shall not be coated except in wet and/or corrosive areas. Wet areasare defined as those where the pipe is immersed or is continually splashed.

Copper piping shall not be coated.

5.4.2 Pipeline Identification

All piping (regardless of piping class or coating requirements) shall be identified with colour codingand flow direction indicators

Colour coding shall be applied either by bands of colour or by full colouring of the pipe inaccordance with the code detailed in Table 5.1.

Colour coded flow indicators shall not be less than 375 mm long. All identification markings shallbe placed at intervals of not less than 8 m on straight runs and adjacent to all junctions, branches,valves, services, appliances, bulkheads, wall penetrations and the like. An exception will be for

uninterrupted lengths of external services (such as in pipe racks) visible along their length.Identification markings shall be placed such that they are clearly visible from the normal accesspoint to the pipe in question.

Hazardous fluid identification shall be provided in accordance with Table 5.2. Coding shallcomprise a 75 mm wide band with diagonal black and yellow strips of equal width for all servicesgreater than 40 NB and a 25 mm wide band for services 40 NB or less in size.

In addition to the above the contained fluid shall be identified on the pipe by words. The words tobe used shall be those listed in Table 5.2 Service Line Description. The Colour of the words shallbe the same as for the pipeline colour coding in Table 5.2.

Standard pipeline identification colours are nominated in Table 5.1 below.


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ISO Colour Name AS2700

Colour Colour Code

Green Jade G21

Silver Grey Silver Grey N24

Brown Golden Tan X53

Yellow-Ochre Sand Y44

Violet Lilac P23

Light Blue Aqua B25

Black Black N61

Safety Red Signal Red R13

Safety Yellow Golden Yellow Y14

Light Orange Orange X15White Off White Y35

Middle Blue Mid Blue B15

Table 5.1 Pipeline Identification Colours

ServiceLine Description

LinePrefix

LineSpecification

ServicePressure

kPa

Hazardous IDRequirement

Colour CodingAS 2700

Acid HCL AC 10 400 Yes P23 Lilac

Acid Spent AS 10 300 Yes P23 Lilac

Barren Carbon BC 02, 07 400 No P23 Lilac

Barren Liquor BL 04, 07 600 No P23 Lilac

Bore Water BW 04,06,07 400 No P23 Lilac

Caustic CA 07, 08 600 Yes P23 Lilac

Collector (generic) /Promoter

COL 04,07 400 Yes N61 Black

Xanthates (SEX) (PAX) 04,06, 07 400 Yes N61 Black

Aerophine COL 04,07 400 Yes N61 Black

Thio Larbamates 04,07 400 Yes N61 Black

Mercaptans COL 04,07 400 Yes N61 Black

Copper Sulphate CUS 06,07 400 Yes P23 Lilac

Cooling Water Return CWR 04 400 No G21 Jade

Cooling Water Supply CWS 04 400 No G21 Jade

Cyanide CY 07, 08 600 Yes P23 Lilac

Depressant (generic) DEP 04,07 400 No N61 Black

Guar. DEP 04,07 400 No N61 Black

CMC DEP 04,07 400 No N61 Black

SMBS DEP 04,07 400 No N61 Black

Diesel (distillate) FO 04, 08 300 Yes X53 Golden Tan

Electrolyte Solution EL 06 600 No P23 Lilac


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LinePrefix

LineSpecification

ServicePressure

kPa



Eduction Water EW 03,04 600 No G21 Jade

Eluate Solution EL 06 600 No P23 Lilac

Fire Water FW 04, 07 600 No R13 Signal Red

Flocculant FL 04, 07 400 No P23 Lilac

Fresh Water WF 04, 05, 07 600 No G21 Jade

Frother (generic) FR 04,07 400 Yes P23 Lilac

MIBC Fr 04,07 400 Yes P23 Lilac

Teric Fr 04,07 400 Yes P23 Lilac

Interfroths Fr 04,07 400 Yes P23 Lilac

Dowfroths Fr 04,07 400 Yes P23 Lilac

Gland Water GW 04, 05 600-2500 No G21 Jade

Gravity Water GRW 04, 07 600 No G21 Jade

High Pressure Air HPA 05, 07 700 No B25 Aqua

Hose Down Process Water HDPW 03, 04, 05, 07 400 No G21 Jade

Instrument Air IA 05 700 No B25 Aqua

Lime Slurry LY 02,07 400 No N61 Black

Liquefied Petroleum Gas LPG 04, 08 140 Yes Y44 SandLoaded Carbon LC 02, 07 400 Yes P23 Lilac

Low Pressure Air LPA 04,05 200 No B25 Aqua

Lube Oil LO 04 300 Yes X53 Golden Tan

Medium Pressure Air MPA 05, 500 No B25 Aqua

Oxygen OX 04, 06 1000 Yes Y44 Sand

Potable Water POT 05, 07 600 No B15 Mid Blue

Pregnant Liquor PL 06 600 No P23 Lilac

Process Slurry PS 01, 07 600 No N61 Black

Process Water PW 03,04,07 600 No G21 Jade

Raw Water RW 03, 04, 05, 07 600 No G21 Jade

Raw Water Filtered RWF 04,05,07 600 No G21 Jade

Sodium Sulphate NAS 06,07 600 No P23 Lilac

Strip Solution SS 04, 06, 07 600 No P23 Lilac

Sump Discharge SU 03, 07 400 No N61 Black

Tailings Slurry TS 01,07 600-1400 No N61 Black

Thermal Oil TO 04, 600 Yes X53 Golden Tan


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LinePrefix

LineSpecification

ServicePressure

kPa



Treated Water TW 05,07 600 No G21 Jade

Vacuum VA 04 - Yes B25 Aqua

Vents V 04, Atmos No - -

Waste Water WW 04,07 400 No N61 Black

Table 5.2 Piping Specification, Hazardous Identifi cation and Piping Color Schedule

Table 5.2 lists a number of common examples of line fluids and line specifications with their lineprefix code, hazardous identification requirements and colour code.

5.5 Line Numbering

Pipelines indicated on engineering flowsheets, piping drawings and line lists are identified by linenumbers. Line numbers provide the following information about the pipeline.

Line Size: Steel Lines - NB eg. 6 (150mm)

Plastic Lines I.P.S eg. 6 (OD 168mm)

Service Description: eg. PS (Process Slurry)

Individual Number: eg. 031 (consecutive three digit numbers for each service)

Line Specification: eg. 4 or 7

Assigned Line Number: 6-PS-031-4 or 6-PS-031-7

Within each service type a different line number is assigned to each individual branch of a pipelineand at each equipment connection. Line numbers have three digits and numbers commence at001 for each service type.

Whenever possible, line numbers are assigned in flow order.

Line numbers are indicated on drawings adjacent to and parallel with the line to which they refer.

Line numbers ending in the codes TI or PP indicate the requirement for insulation of the pipeexternal surface for thermal or personnel protection purposes respectively. Lines so designatedshall be insulated and clad in accordance with Section 8.7 of this specification.

5.6 Nominal Pipe Sizes

In this specification DN is used to designate the size for metallic pipe. Polyethylene (PE) andPolypropylene (PP) pipe sizes are designated by their Iron Pipe Size (I.P.S) ).

The following table presents for information a comparison of pipe sizes expressed in DN (SI metric)and NPS which is the ANSI term (imperial).


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CarbonSteel

NPS (in)

CarbonSteel

DN (mm)

StainlessSteel

DN (mm)

PVCDN (mm)

PEIPS (in) PE

IPS (mm)

1/2 15 15 15

12.7

3/4 20 20 20

19.1

1 25 25 25 1 25.4

11/4 32 32 32 1

1/4 31.8

11/2 40 40 40 1

1/2 38.1

2 50 50 50 2 50.8

3 80 80 80 3 76.2

4 100 100 100 4 101.6

5 125 125 125 5 141.3

6 150 150 150 6 168.3

8 200 200 200 8 219.1

10 250 250 250 10 273.1

12 300 300 300 12 323.9

14 350 350 - 14 355,.6

16 400 400 - 16 406.4

18 450 450 - 18 457.2

20 500 500 - 20 508.0

24 600 600 - 24 609.6

30 750 750 - 30 762.0

32 800 800 - 32 812.8

36 900 900 - 36 914.4

40 1000 1000 - 40 -

42 1050 1050 - 42 1066.8

NPS: Nominal Pipe Size (imperial measurement), ANSI term.

DN: Nominal Diameter (metric measurement), SI term.

I.P.S: Iron Pipe Size as measured for PE and PP pipe (Imperial).


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5.7 Piping Material Specification

5.7.1 Selection of Piping MaterialThe Piping Material Specifications detailed in Section 6.0, define the piping materials that shall beused for each type of service.

Table 5.2 indicates the Line Specification that is required for a particular type of service.

5.8 Valves

5.8.1 Standard Valve Numbering System

Each valve shall be identified on P&IDs and piping drawings by a specific valve number. Anexample of a valve number and an explanation of the format and the codes used to develop thevalve number has been provided below.

The valve size relates to the bore diameter of the valve and is expressed as the pipe/valve DN.The other components of the valve number are selected from a series of codes representing thevarious design parameters that identify the required valve. Legends for the various identifyingcodes for the standard valve types are listed in the following sections.

5.8.2 Standard Valve Descrip tions and Codes

For ease of identification, this specification has assigned codes to a number of standard valvetypes. The following lists define the codes assigned for this specification and relate the codes to anumber of standard valve descriptions.

Valve Type

V1 - Diaphragm Valve

V2 - Butterfly Valve

V3 - Gate Valve

V4 - Ball Valve

V5 - Plug Valve

V6 - Pinch Valve

V7 - Check Valve

V8 - Pressure Relief Valve

V9 - Float Valve

For Example : 40.V4.111

Operation - Lever

Connections - BSP

Valve Series - Cast Steel Body, Stainless Steel Ball & Stem, Reinforced PTFE Seals

Valve Type - Ball Valve

Valve Size - 40 Nominal Bore


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V10 - Constant Flow Valve

V11 - Needle Valves

Valve Series

V1 - Diaphragm Valves

Series 1 Weir Type, Cast Iron Body, Natural Rubber Diaphragm.

Series 2 Straight Through Type, Cast Iron Body, Natural Rubber Diaphragm.

Series 3 Weir Type, Cast Iron Body, EPDM Diaphragm, Rated to 120 Degrees Celsius.

Series 4 Weir Type, Cast Iron Body, Natural Rubber Diaphragm, Soft Rubber Lined.

Series 5 Straight Through Type, Cast Iron Body, Natural Rubber Diaphragm, SoftRubber Lined.

V2 - Butterfly Valves

Series 1 Cast Iron Body, Stainless Steel Disc and Stem, EPDM Seat.

Series 2 Cast Iron Body, EPDM Covered Disc, Stainless Steel Stem.

Series 3 Cast Iron Body, Stainless Steel Disc and Stem, PTFE Seat.

Series 4 Cast Iron Body, PTFE Covered Body and Disc, Stainless Steel Stem.

Series 5 Cast Iron Body and Disc, Stainless Steel Stem, EPDM Seat.

V3 - Gate Valves

Series 1 Wedge Type, Bronze Trim.

Series 2 Wedge Type, Cast Iron Body, Non-Raising Stem, Bronze Trim.

Series 3 Slide Type, Cast Steel Body, Through Port, EPDM Seat, Stainless Steel WettedParts.

Series 4 Knife Type, Stainless Steel Body, Through Port, EPDM Seat, Stainless SteelWetted Parts.

Series 5 Knife Type, Stainless Steel Body, Metal Seat, Stainless Steel Wetted Parts,Deflection Cones.

Series 6 Knife Type, Stainless Steel Body, Resilient Seat, Stainless Steel Wetted Parts,Deflection Cones.

V4 - Ball ValvesSeries 1 1-Piece Stainless Steel Ball and Stem, Reinforced PTFE Seal.

Series 2 3-Piece Stainless Steel Body, Ball and Stem, Reinforced PTFE Seals.

Series 3 2-Piece Stainless Steel Body, Ball and Stem, PTFE Seals, Reduced Bore, FireSafe.

Series 4 UPVC Body, Ball and Stem, EPDM Seals.

Series 5 Polypropylene Body, Ball and Stem, EPDM Seals.

Series 6 2-Piece Carbon Steel Body, Stainless Steel Ball and Stem, Reinforced PTFESeal, Reduced Bore, Fire Safe.

V5 - Plug Valve

Series 1 Parallel Type, Cast Iron, Lubricated.


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V6 - Pinch Valve

Series 1 Open Frame, Natural Rubber Sleeve.

Series 2 Open Frame, Polyurethane Sleeve.

Series 3 Closed Body, Natural Rubber Sleeve.

Series 4 Closed Body, Polyurethane Sleeve.

V7 - Check Valve

Series 1 Bronze Suitable for Horizontal and Vertical Mounting.

Series 2 Duo Flap Type, Steel Body and Plates.

Series 3 UPVC, EPDM Seals.

Series 4 Duo Flap Type, Cast Iron Body and Plates, Buna 'N' Seals.

Series 5 Duo Flap Type, Stainless Steel Body and Plates.

Series 6 Ball Check Type, Polypropylene Body and Ball (up to 2 IPS).

Series 7 Duo Flap Type, Polyethylene Body and Plates.

Series 8 Swing Type, Stainless Steel Body and Plate.

Series 9 Wafer Check Type, Polypropylene Wafer and Plate (3 to 4 OD).

V8 - Pressure Relief Valve

Series 1 Stainless Steel, Full Flow.

Series 2 Polyethylene Dual Air Release and Pressure Relief.

Series 3 Polypropylene, Acid Resistant.

Series 4 Snifter Valve, Stainless Steel Wetted Parts.

V9 - Float Valve

Series 1 Brass Body and Lever, Poly Float.

Series 2 Stainless Steel Body and Lever, Poly Float.

Series 3 Cast Iron Body, Diaphragm c/w Pilot Valve and Poly Float.

V10 - Constant Flow / Pressure Valve

Series 1 Cast Iron Body, Stainless Steel Wetted Parts.

V11 - Needle Valves

Series 1 Cast Steel Body, Stainless Steel Needle, EPDM Seats.

Series 2 Stainless Steel Body, Stainless Steel Needle, EPDM Seats.

Series 3 Cast Steel Body, Stainless Steel Needle, PTFE Seats.

Series 4 Stainless Steel Body, Stainless Steel Needle, PTFE Seats.

Connections

1 - NPT Thread

2 - Flanged D

3 - Flanged E

4 - ANSI 150


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5 - Socket Weld

6 - Butt Weld

7 - Wafer Flange D/E

8 - Wafer Flange ANSI

9 - Lugged Table D

0 - Lugged Table E

S - Special (refer to Design Drawings)

Operations

0 - N/A

1 - Lever

2 - Hand Wheel

3 - Chain Wheel

4 - Gearbox

5 - Solenoid Actuated

6 - Positioner Actuated

7 - Float Operated

8 - Hand Station Actuated (refer to Design Drawings)

6. PIPING SPECIFICATION DATA SHEETS

The pipeline material data sheets contained within this section define the materials of constructionand the physical design parameters for a number of standard pipeline types. The Pipeline MaterialSpecifications selected for a particular duty must be appropriate for the pipeline service listed inTable 5.1 and at the head of each data sheet.


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Piping Material Specification 1

Service: Process Slurry (PS) Tailings Slurry (TS)

DesignConditions:

Temperature (Max): 0 - 80 degrees Celsius

Operating / Test Pressure: 1000 kPa

Material: Carbon Steel Flange Rating: ANSI 150

Code Requirements: ASME B36.10 Sched 40 Corrosion Allowance: Nil

Size Description Standard

Pipe:

2 NB (DN 50) and above Std Wt. Carbon Steel ERW orSeamless Sch 40 Plain ends A106 B

API 5L Gr BASTM A53 Gr B

Fittings:

Elbows 2 NB (DN 50) andabove.

Black Carbon Steel Butt Weld. Std Wt, to be rubber lined, 3 xdiameters unless noted otherwise on the design drawings.

ASTM A 234 - WPB

Tees and Reducers Black Carbon Steel Butt Weld. Std Wt, to be rubber lined ASTM A 234 - WPB

Flanges:

2 NB (DN 50) and above Carbon Steel. Full Face socket weld. ANSI 150

Lining:

Note 3 Natural Rubber, Shore Hardness 35 60. Refer to notes forthickness.

BS 6374

Testing:

All Rubber Lining to be spark tested.Piping to be Hydrostatic tested.

BS 6374 Part 5AS 4041

Bolting:

All Bolts: Hexagonal head, Hot Dipped Galvanized.

Nuts: Hexagonal, Hot Dipped Galvanized.

(ASTM, A306 Grade A)(ASTM A306, Grade A)

Valves: Ball (V4) But terf ly (V2) Check (V7) Gate (V3) Kni fegate (V3)

Series 2 (DN 50) 4(100)

3, 4, 5 or 6

Series 6 NB (DN 150) andabove

3, 4, 5 or 6

Notes:

1. Straight runs of pipe shall be fabricated in standard flanged 6000 mm long, face to face. This is notto be exceeded. Refer to design detail drawings for face to face dimensions.

2. If raised face flanging is used, please ensure the raise face is removed prior to lining.

3. All natural rubber lining to be 6 mm thick unless noted otherwise on the design drawings. Rubbertype should be that specified on the design drawings or GRES approval sought for an alternativesupply.

4. For details of lining @ Flanges, joints etc, refer to GRES Standard Drawings, referred to on thedesign drawings.

5. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with BostikNever-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of

thread.

6. Gaskets normally not required for Rubber lined joints. However where joints are frequentlydismantled use 1.5 mm thick PTFE gaskets.


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7. All spooling should have flanged ends capped for transport and to help prevent damage from ultraviolet radiation prior to erection.

8. Refer to valve selection chart for full valve descriptions.

9. Polyethylene spacer rings may be required for butterfly valves to assist in valve operation.

Branch Connection Table

Nominal size. 50 65 80 100 150 200 250 300 350 400 450 500 600 NB

2 2 3 4 6 8 10 12 14 16 18 20 24 NPS

600 24 S S S S S S B B B B B B A

500 20 S S S S S B B B B B B A

450 18 S S S S S B B B B B A

400 16 S S S S B B B B B A

350 14 S S S S B B B B A

300 12 S S S S B B B A

250 10 S S S B B B A

200 8 S S B B B A

150 6 S S B B A

100 4 B B B A

80 3 B B A

65 2 B A

50 2 A

NB NPS

Table Notes:

1. All Stub-in connections shall be checked in accordance with the pressure design requirements ofANSI/ASME 31.3 and reinforcement (stiffening) shall be provided where necessary.

2. NB: Nominal Bore Size. Measured in Metric.

3. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard.)

A: Equal Tee, Flanged.B: Reducing Tee, Flanged.

C: Threadolet.

D: Reducing Tee and Concentric Reducer.

E: Equal Tee and Concentric Reducer.

F: Sockolet.

S: Stub-in, pipe to pipe connection withoutadditional stiffening. Flanged.


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Service: Barren Carbon (BC) Lime Slurry (LY) Loaded Carbon (LC)

DesignConditions:




Code Requirements: ASME B16.5 Corrosion Allowance: 1 mm


Pipe:

2 (DN 50) and above Black Carbon Steel. Medium Weight.Shouldered Victaulic Ends.

ASME B36.10 Sched 404

Fittings:

Pull BendsY Piece

Fabricated from ERW Std Wt, bends pulled to 3 x diameterc/w victaulic shouldered ends.

API 5L Gr B

Reducers Black Carbon Steel. Std Wt c/w victaulic shouldered ends. ASTM A 234 WPB

Flanges:

2 (DN 50) and above Black Carbon Steel. Full Face socket weld. ANSI 150

Couplings:

All Victaulic couplings to be used at each change of direction.EPDM sealing rings.

BS EN 10241

Gaskets:

All 1.5 mm thick non asbestos fibre, full face. Klingersil C-4430or approved equivalent. Alternatively - Kingerlastic 1.5 mm

thick EPDM, full face.

BS 3663

Bolting:

All Bolts: Hexagonal Head, Hot Dipped Galvanized.


AS1111, Gr 4.6(ASTM, A306 Grade A)AS 1112, Gr 4.6(ASTM A306, Grade A)

Valves: Ball (V4) Butterfly (V2) Check (V7) Diaphragm (V1) Knifegate (V3)

Series DN 50 - 100 2 or 5

Notes:


2. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with BostikNever-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear ofthread.

3. Pull Bends and radius shaped Tees are to be used in all change of directions, this so not todamage the carbon particles in the slurry solution.


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Nominal size. 15 20 25 32 40 50 65 80 100 150 200 250 300 NB

1 1 1 2 2 3 4 6 8 10 12 NPS

300 12

250 10

200 8

150 6

100 4 S S S S S S S

80 3 S S S S S S

65 2 B B B S S

50 2 B B B S

40 1 B B A

32 1 B A

25 1 A

20

15

NB NPS

Table Notes:

1. All Stub-in connections shall be checked in accordance with the pressure design requirements ofAS 4041 and reinforcement (stiffening) shall be provided where necessary.



A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.

S: Stub-in, pipe to pipe connection c/w 3 D pull

bend radius.


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Service: Process Water (PW) Raw Water (RW) Fire Water (FW) Eduction Water (EW)

Hose Down Water - Process Water (HDPW) Sump Discharge (SU)

DesignConditions:

Temperature (Max): 50 180 degrees Celsius


Material: Carbon Flange Rating: ANSI 150



Pipe:

1/2 to 2 DN 15 - 50 Black Carbon Steel. Medium Weight. Screwed and Socketed.

DN 65 - 150 Black Carbon Steel. Medium Weight. Shouldered VictaulicEnds.

8 to 16 (DN 200 350) Std Wt. Carbon Steel ERW. Shouldered Victaulic Ends. API 5L Gr B

Fittings:

to 2 (DN 15 50) Black Carbon Steel. NPT Thread. BS1740, BS1722

DN 65 and above Black Carbon Steel. Std Wt. c/w Victaulic Shouldered Ends.

Flanges:

to 2 (DN 15 50) Black Carbon Steel. Full Face, threaded to NPT. ASME B16.5, ANSI 150,ANSI B2.1

DN 65 and above Black Carbon Steel. Full Face socket weld. ASME B16.5, ANSI 150

Couplings:

to 2 (DN 15 50) Black Carbon Steel. Viton Seat. BS EN 10241

DN 65 - 350 Victaulic Ring Type A c/w Galvanised Victaulic Couplings.Sealing Ring EDPM.

Gaskets:

All 1.5 mm thick non asbestos fibre, full face. Klingersil C-4430 orapproved equivalent. Alternatively - Kingerlastic 1.5 mm thickEPDM, full face.

BS 3663

Bolting:




Valves: Ball (V4) Butterfly (V2) Check (V7) Diaphragm (V1) Knifegate(V3)

Series 2 (DN 15 50)

1 or 2 1 2 or 8 1

Series 2 (DN 65) andabove

3 or 6 1 1

Notes:

1. Threads shall be sealed using Loctite 567 (Thread Paste) or Teflon thread sealing tape (ThreadTape) or an approved equivalent sealing compound.

2. Refer to valve selection chart for full valve descriptions.3. Use of barrel unions up-to and including 2 (50 NB) except where connected to flanged

components.


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4. Provide barrel unions or flanged connections at appropriate distances and at change of direction toallow or where required to allow for disassembly.



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Nominal size. 15 20 25 32 40 50 65 80 100 150 200 250 300 NB

1 1 1 2 2 3 4 6 8 10 12 NPS

300 12 C C C C C C S S S S B B A

250 10 C C C C C C S S S B B A

200 8 C C C C C C S S S B A

150 6 C C C C C C S S B A

100 4 C C C C C C S B A

80 3 C C C C C C B A

65 2 C C C C C B A

50 2 B B B B B A

40 1 B B B B A

32 1 B B B A

25 1 B B A

20 B A

15 A

NB NPS

Table Notes:




A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.

S: Stub-in, pipe to pipe connection without

additional stiffening.


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Service: Process Water (PW) Raw Water (RW) Fire Water (FW) Bore Water (BW)

Barren Liquor (BL) Fresh Water (WF) Collectors (COL) Vacuum (VA)

Flocculant (FL) Gravity Water (GRW) Lube Oil (LO) Thermal Oil (TO)

Oxygen (OX) Diesel (Distillate)(FO) Waste Water (WW) Depressant (DEP)

Gland Water (GW) Vents (V) Frother (FR)

Cooling Water Supply (CWS) Cooling Water Return (CWR)

Hose Down Water - Process Water (HDPW) Liquefied Petroleum Gas (LPG)

Raw Water Filtered (RWF) Low Pressure Air (LPA)

DesignConditions:




Code Requirements: ASME B36.10 Corrosion Allowance: Nil


Pipe:

2 (DN 15 50) Black Carbon Steel. Medium Weight. Screwed and Socketed. ASME B36.10

2 6 (DN 65 150) Black Carbon Steel. Medium Weight. Butt Weld. ASME B36.10

8 (DN 200) and above Std Wt. Carbon Steel ERW. Butt Weld. API 5L Gr B

Fittings:

DN 15 50 Black Carbon Steel. NPT Thread. ANSI B2.1

DN 65 and above Black Carbon Steel. Std Wt. Butt Weld

Flanges:

DN 15 50 Black Carbon Steel. Full Face threaded to BSP. ASME B16.5, ANSI 150

DN 65 and above Black Carbon Steel. Full Face Slip On. ASME B16.5, ANSI 150

Couplings:

DN 15 50 Black Carbon Steel. Viton Seat. BS EN 10241

Gaskets:


BS 3663

Bolting:




Valves: Ball (V4) But terf ly (V2) Check (V7) Diaphragm (V1) Kni fegate (V3)

Series 2(DN 15 50)

1, 2 or 3 1 2 or 8 1 or 2


3 or 4 1 2, 4 or 5 1 or 2

Notes:



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3. Use of barrel unions up-to and including 2 (50 NB) except where connected to flanged

components.



6. LPG line up to 1 (25NB) only.


Nominal size. 15 20 25 32 40 50 65 80 100 150 200 250 300 NB

1 1 1 2 2 3 4 6 8 10 12 NPS





100 4 C C C C C C S B A


65 2 C C C C C B A

50 2 C C B B B A

40 1 C C B B A

32 1 B B B A

25 1 B B A

20 B A

15 A

NB NPS

Table Notes:




A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.

S: Stub-in, pipe to pipe connection withoutadditional stiffening.


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Service: Low Pressure Air (LPA) Instrument Air (IA) Raw Water (RW) Gland Water (GW)

Fire Water (FW) Fresh Water (WF) Treated Water (TW)

High Pressure Air (HPA), Medium Pressure Air (MPA),

Hose Down Water Process Water (HDPW)

DesignConditions:



Material: Galvanised Carbon Steel Flange Rating: ANSI 150

Code Requirements: ASME B36.10 Corrosion Allowance: Nil


Pipe:

DN 15 - 50 Galvanised Carbon Steel. Medium Weight. Screwed andSocketed.

1. AS 1074

DN 65 - 150 Galvanised Carbon Steel, Medium Weight, Plain Ended orRolled Grooved Victaulic Ends.

2. AS 1074

DN 200 and above Std Wt. Carbon Steel ERW. Hot Dipped Galvanised. API 5L Gr B

Fittings:

DN 15 - 50 Galvanised Carbon Steel. NPT Thread. ANSI B2.1

DN 65 and above Galvanised Carbon Steel. Std Wt c/w Rolled Grooved VictaulicEnds.

Flanges:

to 2 (DN15 50) Galvanised Carbon Steel. Full Face, threaded to BSP. ASME B16.5, ANSI 1502 (DN 65) and above Galvanised Carbon Steel. Full Face Slip On. ASME B16.5, ANSI 150

Couplings:

tp 2(DN 15 50) Zinc-Coated Carbon Steel. Viton Seat. BS EN 10241

Gaskets:


BS 3663

Bolting:





Series to 2 (DN 15 50)

1, 2 or 3 1 2 or 8 2


3 or 4 1 2, 4 or 5 2

Notes:



3. Use of barrel unions up-to and including 2 (50 NB) except where connected to flangedcomponents.


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5. All nominated water services (WR, GW, FW, POT and HDPW) are only for line sizes up-to andincluding 2 (50 NB) only. For lines above this refer to pipe specification 3 or 4.


7. Not for use on drinking water service. AS 3500 precludes the use of galvanized pipe in drinkingwater service.


Nominal size. 15 20 25 32 40 50 65 80 100 150 200 250 300 NB

1 1 1 2 2 3 4 6 8 10 12 NPS





100 4 C C C C C C S B A


65 2 C C C C C B A

50 2 B B B B B A

40 1 B B B B A

32 1 B B B A

25 1 B B A

20 B A

15 A

NB NPS

Table Notes:



3. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard)

A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.




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Service: Oxygen (OX) Eluate Solution (EL) Pregnant Liquor (PL) Strip Solution (SS)

Cyanide (CY) Caustic (CA) Sodium Sulphate (NAS) Bore Water (BW)

Copper Sulphate (CUS) Collectors (COL)

DesignConditions:

Temperature (Max): 120 degrees Celsius

Operating Pressure: 500 kPa max Test Pressure: 1000 kPa

Material: Stainless Steel 316 L Flange Rating: ANSI 150

Code Requirements: ASTM A312 Corrosion Allowance: 1 mm


Pipe:

to 2(DN 15 50) Stainless Steel, Gr 316L, Schedule 40S, SMLS Plain ends. ASTM A312

GR TP 306L

2 8 (DN 65 200) Stainless Steel, Gr 316L, Schedule 10S, ERW, Bevel ends. ASTM A312GR TP 306L

Fittings:

2 DN 15 - 50 Forged, Class 3000, BSP or Socket Weld 3000# ASTM A182

2 tp 8 DN 65 and 200 Butt Welded, Schedule 10S ASTM A403M

Flanges:

2 DN 15 - 50 Stainless Steel. Full Face, threaded to NPT. ASME B16.5, ANSI 150

2 (DN 65) and above Stainless Steel. Full Face Slip On. ASME B16.5, ANSI 150

Couplings:

DN 15 - 50 Stainless Steel. Viton Seat. BS EN 10241

Gaskets:


BS 3663

Bolting:

General Application Bolts: Hexagonal Head, Hot Dipped Galvanized.



Special Application SS Bolts, Studs and Nuts. ASTM A 193 GR B8ASTM A 194 GR8


Series 2(DN 15 50)

2 or 3 2, 3 or 4 5 or 8


3 2, 3 or 4 8

Notes:



3. Use of Stainless Steel barrel unions up-to and including 2 (50 NB) except where connected toflanged components.


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5. Galvanised steel, Stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread.

6. The use of Pipe specification 6, for any service where the designated route is in area whereonerous conditions exist. An example of this is on top of Leach and Adsorption Tanks, below thetop of platform steelwork.

7. 1.5 mm thick non asbestos fibre, full face. Klingersil C-8200 or approved equivalent for Eluate, StripSolutions and Pregnant Liquor, the other services can be Klingersil C-4430 or approved equivalent.


Nominal size. 15 20 25 32 40 50 65 80 100 150 200 250 300 NB

1 1 1 2 2 3 4 6 8 10 12 NPS

300 12

250 10



100 4 C C C C C C S B A


65 2 C C C C C B A

50 2 B B B B B A

40 1 B B B B A

32 1 B B B A

25 1 B B A

20 B A

15 A

NB NPS

Table Notes:




A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.




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Service: Process Slurry (PS) Sump Discharge (SU) Barren Carbon (BL) Barren Liquor (BL)

Flocculant (FL) Cyanide (CY) Caustic (CA) Process Water (PW)

Raw Water (RW) Bore Water (BW) Fresh Water (WF) Potable Water (POT)

Fire Water - Buried (FW) Collector (COL) Copper Sulphate (CUS) Depressant (DEP)

Frother (FR) Gravity Water (GRW) Loaded Carbon (LC) Lime Supply (LY)

Sodium Sulphate (NAS) Treated Water (TW) Waste Water (WW)

Tailings Slurry - Refer Design - PON Rating (TS) High Pressure Air Buried (HPA)

Hose Down Water Process Water (HDPW)

DesignConditions:

Temperature (Max): 20 degrees Celsius, 40 degrees Celsius, 60 degrees Celsius.

Operating / Test Pressure: 1000 kPa @ 20 C, 750 kPa @ 40 C, 560 kPa @ 60 C.

Material: High Density Polyethylene PE 4710 Flange Rating: ANSI 150

Code Requirements: ASTM D2239 Corrosion Allowance: Nil


Pipe:

-6 IPS (20 160 OD) High Density Polyethylene PE 4710 DR 17 (125psi):Continuous Coil.

ASTM D2239

4 24 IPS (110 630OD)

High Density Polyethylene PE 4710 DR 17 (125psi): StraightLengths.

ASTM D2239

Fittings:

2 (20 75 OD) PE, Plasson or Equivalent Type Compression Fittings. AS 4129, ASTM D3139?

2 24 (50 630 OD) PE, Butt Fusion Weld Connections, Stub Ends, Short RadiusElbows, Sweep Bends, Reducers, Fabricated Tees and YSections.

AS 4129, ASTM D3139?

Flanges:

-2 (20 63 OD) Galvanised Carbon Steel. Full Face, threaded to BSP (Plassonmale adaptors).

ASME B16.5, ANSI 150

2 24(50 630 OD) Polyethylene Stub Ends c/w Galvanised Carbon Steel BackingRing.

ASME B16.5, ANSI 150

Couplings:

Victaulic Shoulder c/w Galvanised Victaulic Coupling. Refer toNote 6.

Gaskets:

All 1.5mm or 3.0mm thick full face. Insertion Rubber. BS 3663, ASTM F477

Bolting:

All Bolts: Hexagonal head, Hot Dipped Galvanized.




Series DN 15 - 50 1, 2 & 3 & 6 1 2 or 8 1 or 2 4

Series DN 65 and above 2, 3, 4, 5 & 6 1 2, 4 or 5 1, 2, 3, 4 & 5 3, 4, 5 & 6

Notes:

1. PE 4710 DR 17 (125 psi) is the minimum PE piping design class for pressure applications withinthe process plant.


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2. Diameters nominated are pipe, fitting IPS., (inside nominal bore)

3. Compression fittings shall not be used on any toxic or corrosive fluids. For example Caustic,

Cyanide, lime.

4. Nominal pressure rating for all compression fitting used to be PN16.(230psi)

5. Short radius elbows are only to be used on non slurry lines. (Water services etc)

6. All Slurry service lines to have 3 D Sweep Bends with victaulic shoulder couplings for ease ofbreaking line for maintenance purposes. This also includes Sump Lines.

7. Fabricated Lobster backs not to be used.

8. Pressure ratings shall be reduced with increased temperature in accordance with Manufacturesrecommendations.

9. Where buried services are installed, insure pipe routes are fully continuous butt weld circuits.Survey to be done prior to backfilling of lines.

10. Fire Water lines (buried) require change in spec a minimum of 200 mm below ground whenprotruding to the surface. Check design drawings on the designed pressure rating.

11. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with BostikNever-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear ofthread. Where bolts are used underground ensure they are completely wrapped with Denso Tape.

12. Where Butterfly Valves are used inline please ensure valve disc will open freely. Site engineer toadvise if stub end can be bevelled to suit or poly spacer is required for that application.


Nominal size. 20 25 32 40 50 63 75 90 110 160 225 280 315 OD

1 1 1 2 2 3 4 6 8 10 12 NPS

315 12 C C C C C C D D D B B B A

280 10 C C C C C C D D B B B A

225 8 C C C C C C B B B B A

160 6 C C C C C C B B B A

110 4 C C C C C C B B A


75 2 C C C C C B A

63 2 B B B B B A

50 1 B B B B A

40 1 B B B A

32 1 B B A

25 B A

15 A

OD NPS

A: Equal Tee.

B: Reducing Tee.

C: Tapping Saddle - Threadolet.



F: Sockolet.




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Table Notes:


2. IPS: Iron Pipe Size. Measured in Imperial, and relates to the nominal internal bore of the pipe..



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Service: Liquified Petroleum Gas (LPG) Diesel Distillate (DS) Cyanide (CY) Caustic (CA)

DesignConditions:

Temperature (Max): 80 degrees Celsius

Operating Pressure: 1000 kPa max Test Pressure: 1500 kPa

Material: Carbon Steel Flange Rating: Class 150 RF

Code Requirements: AS 4041 Corrosion Allowance: 1 mm


Pipe:

2 (DN 15 50) Black Carbon Steel ERW Schedule 80. API 5L Gr BANSI B 36.10

2 (DN 65) and above Black Carbon Steel ERW Schedule 40. API 5L Gr B

ANSI B 36.10Fittings:

to 2 (DN 15 50) Forged 3000# Black Carbon Steel.Socket Weld.

ASTM A 105ANSI B 16-11

2 (DN 65) and above Black Carbon Steel. Std Wt Butt Welded ASTM A 234ANSI B 16-11

Flanges:

2 (DN 15 50) Black Carbon Steel, Raised face Slip on. ASTM A 105ANSI B 16.5

2 (DN 65) and above Black Carbon Steel, Raised face Slip on. ASTM A 105ANSI B 16.5

Couplings:N/A

Gaskets:

All 1.5 mm thick non asbestos fibre, ring face. Klingersil C-4430 orapproved equivalent.

ANSI/ASME B 16.21

Bolting:

All Studs or Bolts: Hexagonal head, Hot Dipped Galvanized.Nuts: Hexagonal, Hot Dipped Galvanized.

ASTM A 193 GR 7ANSI/ASME B 1.1ASTM A 194 GR 2H


2(DN 15 50) 1, 2 & 3 & 6 1 2 & 8 1 & 2

2 (DN 65) and above 1, 2, 3 & 6 1 2, 5 & 8 1 & 2

Notes:



3. Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread.

4. All pipe that is buried to be fully wrapped with Denso Tape in accordance with ManufacturesSpecifications.


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Nominal size. 15 20 25 32 40 50 65 80 100 150 200 250 300 NB

1 1 1 2 2 3 4 6 8 10 12 NPS





100 4 C C C C C C S B A


65 2 C C C C C B A

50 2 B B B B B A

40 1 B B B B A

32 1 B B B A

25 1 B B A

20 B A

15 A

NB NPS

Table Notes:




A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.



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Not Used


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Service: 35% Hydrochloric Acid (AC) 3% Hydrochloric Acid (AC) Spent Acid (AS)

DesignConditions:

Temperature (Max): 20 degrees Celsius, 40 degrees Celsius, 60 degrees Celsius.

Operating / Test Pressure: 1000 kPa @ 20 C, 750 kPa @ 40 C, 480 kPa @ 60 C

Material: Polypropylene PN 10 Flange Rating: Table E

Code Requirements: AS 4041 Corrosion Allowance: 1 mm


Pipe:

20 110 OD Grey Polypropylene PN 10. Straight Lengths. DIN 16962

Fittings:

20 63 OD Socket Weld Fusion Jointing. DIN 16962

90 110 OD Butt Weld Fusion Connections, Stub Ends, Short RadiusElbows, Sweep Bends, Reducers, Fabricated Tees and YSections.

DIN 16962

Flanges:

20 110 OD Polypropylene Stub Ends c/w Galvanised Carbon Steel BackingRing.

AS 2129 Table E

Pipe Joints:

Socket Weld Fusion Jointing and/or Butt Weld FusionConnections.

Gaskets:

All 1.5 mm thick non asbestos fibre, full face. Klingersil C-8200 or

approved equivalent.

BS 3663

Bolting:

All Bolts: Hexagonal head, Hot Dipped Galvanized.Nuts: Hexagonal, Hot Dipped Galvanized.

AS 1111, Gr 4.6AS 1112, Gr 4.6


DN 15 - 50 4 & 5 4 3, 6 & 7

DN 65 and above 4 & 5 4 3, 6 & 7

Notes:

1. Grey Polypropylene PN10 is the minimum PP piping design class for pressure applications within

the process plant.

2. Diameters nominated are pipe, fitting OD. (outside diameter)

3. Pressure ratings shall be reduced with increased temperature in accordance with Manufacturesrecommendations.

4. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with BostikNever-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear ofthread. Where bolts are used underground ensure they are completely wrapped with Denso Tape.

5. Where Butterfly Valves are used inline please ensure valve disc will open freely. Site engineer toadvise if stub end can be bevelled to suit or poly spacer is required for that application.


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Nominal size. 20 25 32 40 50 63 75 90 110 160 225 280 315 OD

1 1 1 2 2 3 4 6 8 10 12 NPS

315 12

280 10

225 8

160 6

110 4 C C C C C C B B A


75 2 C C C C C B A

63 2 B B B B B A

50 1 B B B B A

40 1 B B B A

32 1 B B A

25 B A

20 A

OD NPS

Table Notes:


2. OD: Outside Diameter of Pipe Size. Measured in Metric.


A: Equal Tee.

B: Reducing Fabricated Tee.

C: Tapping Saddle - Threadolet.



F: Sockolet.




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Service: High Pressure Air (HPA)

DesignConditions:



Material: Galvanised Carbon Steel Flange Rating: ANSI 150

Code Requirements: AS 4041 Corrosion Allowance: Nil


Pipe:

2 (DN 15 -150) Galvanised Carbon Steel. Schedule 40 ASTM A53 Gr B, API 5LGr BANSI B 36.10

Fittings:- 2 (DN 15 50) Galvanised Forged Carbon Steel. 3000#. NPT Thread. ASTM A 105

ANSI B 16.11ANSI B1.20.1

2 6 (DN 65 -150) Galvanised Carbon Steel. Schedule 40. Butt Welded ASTM A 234ANSI B 16.9

Flanges:

2 6 (DN 65 -150) Galvanised Carbon Steel. Table E. Flat Face. Slip on (Note 1) ASTM A 105ANSI B 16.5

Gaskets:


BS 3663

Bolting:





Series - 2 (DN 15 50)

1

Series 2 6 (DN 65 -150)

1,3 8

Notes:

1. ANSI Class 150 flanges

2. Fabricated spools shall be hot dip galvanized





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Nominal size. 15 20 25 32 40 50 65 80 100 150 200 250 300 NB

1 1 1 2 2 3 4 6 8 10 12 NPS

300 12

250 10

200 8


100 4 C C C C C C S B A


65 2 C C C C C B A

50 2 B B B B B A

40 1 B B B B A

32 1 B B B A

25 1 B B A

20 B A

15 A

NB NPS

Table Notes:



3. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard)

A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.



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Service: Process Water (PW)

High Pressure Air (HPA)

DesignConditions:



Material: Carbon Steel Flange Rating: Class 900



Pipe:

1 (DN 15 -40) Carbon Steel. Schedule 80. Socket Welded ASTM A53 Gr B, API 5LGr B

ANSI B 36.102 6 (DN 50 -150) Carbon Steel. Schedule 80. Butt Welded ASTM A53 Gr B, API 5L

Gr BANSI B 36.10

Fittings:

1 : (DN 15 40) Black Carbon Steel Forged 3000# Carbon Steel. NPT SocketWelded.

ASTM A 105ANSI B 16.11

2 6 (DN 50 -150) Carbon Steel. Schedule 80. Butt Welded ASTM A 234ANSI B 16.9

Flanges:

1 6 (DN 25 150) Black Carbon Steel. ANSI Class 900.Raised Face. ASTM A 105ANSI B 16.5

Gaskets:

All Spiral Wound Type. ANSI B 16.20

Bolting:

All StudsNuts

ASTM A193 Gr B7ASTM A194 Gr 2H

Valves: Note 1 Ball (V4) Plug (VS) Check (VS)

Series 1 (DN 15 40)

S S

Series2- 6 (DN 50 150)

S S S

Notes:



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Nominal size. 15 20 25 32 40 50 65 80 100 150

1 1 1 2 2 3 4 6

150 6 F F F F F F S S B A

100 4 F F F F F F S B A

80 3 F F F F F F B A

65 2 F F F F F B A

50 2 F F B B B A

40 1 F F B B A

32 1 B B B A

25 1 B B A

20 B A

15 A

NB NPS

A: Equal Tee.

B: Reducing Tee.

C: Threadolet.



F: Sockolet.



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7. FABRICATION / MANUFACTURE

7.1 General

Work shall be carried out in accordance with ANSI/ASME B31.3 and good engineering practice byqualified trades persons. The work shall be properly documented and records prepared andcontinuously updated as necessary, for proper execution and control of fabrication. All materialsshall be in accordance with all parts of this specification and the piping specification data sheetsspecified.

7.2 Shop Fabrication

7.2.1 Workshop Requirements

Adequate under cover workshop facilities shall be provided to ensure a safe, efficient andcontinuous preparation of piping spools for welding and assembly. Surface preparation should beundertaken in a separate area away from the fabrication workshop.

7.2.2 Progress Control

Progress control and planning documentation shall be maintained to plan, control and report allfacets of pipe fabrication. The documentation to be prepared will include but not be limited to thefollowing.

Preparation of pipe spool drawings.

Confirmation of material availability

Surplus or shortage of materials if they have been free issued.

Shop fabrication progress per spool. Lining progress per spool (if required).

Inspection of works quality.

Testing of spools (if required).

Non destructive examination (If required).

Weld repair and rework (where necessary).

Revision to any issued drawings.

Hot dipped galvanising (if required).

Surface preparation and coating.

Freight (shipping) records.

7.2.3 General Fabrication

Linear dimensions shall not deviate by more than 3 mm from the indicated dimension.

Where onsite prefabrication is carried out by the contractor, it shall be the responsibility ofthe contractor to verify the accuracy of any given dimensions and make due allowance forsite closures to cover the eventuality of site obstructions and dimensional errors of aminor nature.

The faces of flanges and unions shall be square to the pipeline to which they are fitted.

Flanges supplied for connections to vendor equipment items, shall be the same as the

flange type fitted to the equipment. If raised faced flanges are supplied on the equipmentthen matching raised face flanges are to be supplied on the fabricated pipework.


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All flanges shall be fitted to pipe with holes off centre unless specified differently on thedesign drawing. The angular misalignment of flanged bolt holes shall not exceed 1.5 mm

measured at the bolting pitch circle. Field fits where specified on drawings shall be supplied with matching flange and a

nominated amount of "green" pipe, to allow for fitting and correct alignment on site.

Field fit welds where specified on drawings shall have one spool fully prepared for buttwelding with the mating spool and with a nominated amount of "green" left on the pipe, forsite trimming.

3000 lb sockolets or weldolets to A105 grade II shall be used on connections of 50 mmand under. No screwed sockets shall be used unless permission has been granted bythe company representative.

All prefabricated pipe spooling shall be adequately marked to ensure proper installation.Isometric drawings shall be marked with the spool numbering system and shipped to site

with pipe spooling.

Materials may be formed to the required shape by any process that will not impair itsquality. Where specified, items shall be heat treated after forming is completed.

Only where specified on design drawings a segmented bend or "lobster back" may beused. Segmented bends shall be manufactured by butt welding together segments ofpipe shaped to produce the required bend. Wherever possible the segments shall betaken from the same length of pipe.

Each segment of a segmented bend shall not exceed 30 degrees, unless specified oragreed to by the company representative.

Formed or segmented bends shall be manufactured without distortion of the cross sectionof the pipe or the pipe wall. Thinning of the pipe wall below the minimum thickness is not

permitted.

7.3 Welding

The welding of butt joints using oxy-acetylene and filler wire shall be carried out inaccordance with AWS DIO.

Manual arc welding of butt and branch joints shall be carried out in accordance with AWSDIO.

Welder qualifications shall conform to AWS ATF.

The contractor is to provide documentation detailing welding procedures and the format ofthe proposed ITP/MDRs for approval by the company representative prior to

commencement of any work. Production Welder Qualification - The first weld during production should be tested and

added to the MDR as a record of the welder's qualification to the approved procedure.

The general weld procedures adopted for pipework fabrication in workshops or on siteshould be equivalent to those noted below:

a. Procedure for Slip On (SO) flanges and spinn ing flange backing rings shallbe:

Run 1.6 mm FLAW wire ESAB 71 T or equivalent.

b. Procedure for butt weld fittings GTAW/FLAW:

Root Run 2.4 mm GTAW solid wire LW1.Intermediate Run 1.2 or 1.6 mm FLAW wire ESAB 71 T or equivalent.

Capping Run 1.2 or 1.6 mm FLAW wire ESAB 71 T or equivalent.


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c. Procedure for butt weld fittings GMAW/FLAW:

Root Run 0.9 mm GMAW solid wire L or equivalent.

Intermediate Run 1.2 or 1.6 mm FLAW wire ESAB 71 T or equivalent.

Capping Run 1.2 or 1.6 mm FLAW wire ESAB 71 T or equivalent.

Following acceptance of a welders qualification by the company representative, or onsatisfactory completion of a special welding test that may from time to time be required,the welder will be advised of his personal identification mark. The mark shall be stampedon every weld he performs in systems where examination of the completed weld is arequirement. The welder identification mark will only be assigned for a particular task thatwill be defined at the time of issue.

General Preparation f or Welding

Pipe may be cut either by mechanical means or by flame cutting, depending on the typeof material to be cut. For carbon steel, flame (or arc) cutting and bevelling of the cut edgeis only acceptable if the cut is reasonably smooth, true and all oxides are removed fromthe flame cut surfaces by grinding. After flame cutting the bevelled end, preparation shallbe ground back to bright and sound metal.

For stainless steel, plasma cutting and machining of the cut end is preferred. Grindingback to bright, sound metal is required. The pipe ends cannot be machined. Flamecutting is not allowed.

All welding shall be undertaken in areas adequately protected from inclement weatherconditions such as rain, wind, dust and the like.

All end preparations and adjacent areas, 50 mm either side of the weld, shall be

thoroughly cleaned and degreased prior to welding.End preparation for butt welding shall be in accordance with ANSI/ASME B16.25.

Defective or damaged weld preparations (bevels) shall be repaired. Use of hot or coldhammering as a means for repair is prohibited.

General Preparation f or Welding of Flanges

Slip on flanges shall be positioned so that the end of the pipe is recessed from the flange,a distance equal to the lesser of the pipe wall thickness plus 1.5 mm or 8 mm. Sealwelding for slip on flange shall be carefully applied in order to avoid refacing the flange.

Pipes for insertion in slip on flanges shall be cut square, within 0.5 mm.

Socket Weld Pipe Systems

Pipe for insertion in a socket weld joint shall be cut square within 0.5 mm. A minimumgap of 1.6 mm shall be maintained between the end of the pipe and the bottom of thesocket.

Socket Weld Valves

Because of the possibility of seat distortion due to welding heat, the valve stems shall bein the open position prior to commencement of welding. This is applicable to all valvetypes and sizes.


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7.4 Inspection and Testing

InspectionAll fabrication shall be inspected in accordance with ANSI B31.3 and this specification.Inspection and Test Plan (ITP) shall be submitted for written approval of the companyrepresentative.

The ITP shall have clearly marked:

- Project Description.

- Client.

- Purchase Order.

- Step by step work procedures complete with review and hold points and

acceptance columns for contractor and client.

- Inspection shall also include visual examination and any other additionalexamination necessary to ensure compliance with this specification. NDT andpressure test records shall be submitted to the manager for approval.

The level of examination required for each piping material specification has beennominated in Schedule 8. Inspection and testing for the quality of fabrication must becarried out prior to any painting or coating is applied. Non-destructive testing of weldsshall be carried out after final heat treatment is completed. All radiography shall beconducted by competent radiographic examiners in accordance with a NATA approvedprocedure. The cost of weld repairs as a result of failures detected by radiographytogether with the cost of re-examination will be at the contractors account.

The welder whose work does not pass radiographic examination shall have double thespecified number of welds examined. The additional welds to be tested shall be chosenfrom those welds not previously examined. If additional welds tested comply then thecosts of this additional testing will be borne by the Company. Should the additional weldstested not comply, all remaining welds having a specification subject to some form ofradiography shall be examined and repaired at the contractors cost. The welderresponsible for the failed welds shall cease to be recognised as being coded in thatparticular procedure.

Schedule 8 - General Requirements for Testing Both Off Site and On Site.

Meaning of Abbreviations:

RT Radiographic Testing

MPT Magnetic Particle Testing

HT Hydrostatic Testing

LPT Liquid Penetrant Testing

WTWP Water Testing at Working Pressure

PT Pneumatic Testing

FWT Field Weld Testing


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PipingMaterial

Specification

Piping MaterialInspection and Testing Requirements

Off Site Fabrication On Site Fab / Installation

1. Carbon Steel Rubber Lined 10% RT at Random50% Visual Inspection100% Spark Test10% MPT at Random

100% WTWP

2. Carbon Steel N/A 50% Visual Inspection100% WTWP

3. Carbon Steel N/A 30% Visual Inspection100% HT

4. Carbon Steel (ServiceWaters)

5% MPT on Fillet Welds20% Visual Inspection

30% Visual Inspection100% HT

Carbon Steel (oils and

Gases)

10% RT at Ra

ts12 technical specification - piping

Documents

piping material specifications

pp rds4

pp rds3

construction pp rds1

construction pp rds0

minor corrections

minor update pms

santa elena ss sd6