Ts12 Technical Specification - Piping

TECHNICAL SPECIFICATION
TS-12
Piping SANTA ELENA - MEXICO
Revision 7 6 5 4 3 2 1 0
Issue Date 07-02-13 6-Apr-10 18-Feb-10 15-Feb-08 17-Oct-07 23-Jul-07 21-Jun-07 8-Mar-07
Issue Purpose Project Specific 300010 Santa Elena Minor update PMS 12 Bolting: Stud & Nuts Standard Add Piping Material Specifications 11 and 12 Minor corrections to Piping Material Specifications 4, 6, 7, 10 Minor corrections and update to V7 Check Valves Issued for construction Issued for construction Issued for construction
Prepared By SS LK PP PP MS PP PP PP
Approved By SD PDS RDS RDS PP RDS RDS RDS
TECHNICAL SPECIFICATION PIPING

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TABLE OF CONTENTS
1. 2. 3. 4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6. SCOPE ................................................................................................................................................ 4 REFERENCE CODES AND STANDARDS ........................................................................................ 4 ABBREVIATIONS............................................................................................................................... 6 RELATED DOCUMENTS ................................................................................................................... 7 DESIGN DETAILS .............................................................................................................................. 7 Pipework ............................................................................................................................................ 7 Flanges ............................................................................................................................................... 8 Fittings ............................................................................................................................................... 8 Painting and Service Identification ................................................................................................. 9 Line Numbering ............................................................................................................................... 12 Nominal Pipe Sizes ......................................................................................................................... 12 Piping Material Specification ......................................................................................................... 14 Valves ............................................................................................................................................... 14 PIPING SPECIFICATION DATA SHEETS ....................................................................................... 17 Piping Material Specification 1 .......................................................................................................... 18 Piping Material Specification 2 .......................................................................................................... 20 Piping Material Specification 3 .......................................................................................................... 22 Piping Material Specification 4 .......................................................................................................... 25 Piping Material Specification 5 .......................................................................................................... 27 Piping Material Specification 6 .......................................................................................................... 29 Piping Material Specification 7 .......................................................................................................... 31 Piping Material Specification 8 .......................................................................................................... 34 Piping Material Specification 9 .......................................................................................................... 36 Piping Material Specification 10 ........................................................................................................ 37 Piping Material Specification 11 ........................................................................................................ 39 Piping Material Specification 12 ........................................................................................................ 41 7. 7.1 7.2 7.3 7.4 8. 8.1 8.2 8.3 8.4 8.5 FABRICATION / MANUFACTURE .................................................................................................. 43 General ............................................................................................................................................. 43 Shop Fabrication ............................................................................................................................. 43 Welding ............................................................................................................................................ 44 Inspection and Testing ................................................................................................................... 46 INSTALLATION, ERECTION AND CONSTRUCTION (SITE WORKS) ..........................................48 General Requirements .................................................................................................................... 48 Cleanliness and Protection ............................................................................................................ 48 Installation of Valves....................................................................................................................... 49 Piping for Rotating Equipment ...................................................................................................... 49 Flanged Joints and Bolting ............................................................................................................ 50
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8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 9. 9.1 9.2
Pipe Supports .................................................................................................................................. 50 Insulated Piping ............................................................................................................................... 51 Stainless Steel Piping ..................................................................................................................... 53 Plastic Piping ................................................................................................................................... 53 Rubber Lining .................................................................................................................................. 53 Polyurethane Lining ........................................................................................................................ 54 Galvanised Piping ........................................................................................................................... 54 Mining Hose ..................................................................................................................................... 54 Under Ground Piping ...................................................................................................................... 54 COMMISSIONING AND TESTING ................................................................................................... 56 Pressure Testing ............................................................................................................................. 56 Cleaning and Reinstatement .......................................................................................................... 58
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1.
SCOPE This specification defines the materials of construction, connection types and protective coatings required for piping components and valves for use in the construction of process and services piping systems. It also defines the requirements for fabrication and installation of piping system components. Where conflict between this specification and issued for construction drawings exists, the information provided on issued for construction P&IDs and piping drawings shall take precedence over this specification. Any instance of conflict between issued for construction drawings and this specification 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 AS 1112 AS 1345 AS 1444 AS 1477 AS 1594 AS 1657 AS 1722 AS 2129 AS 2528 AS 3500 AS 4041 AS 4130 AS 4131 BS 6374 BS 6755 API 5L ASTM A53 ASTM A105 ASTM A181 ASTM A182 ASTM A193 ISO Metric Hexagon Bolts and Screws Product Grade C Bolts ISO Metric Hexagon Nuts Style 1 Product Grade A and B Identification of the Content of Pipes, Conduits and Ducts Wrought Alloy Steels PVC Pipes and Fittings for Pressure Applications Hot-Rolled Steel Flat Products Installation and Maintenance of Steel Pipe Systems for Gas Pipe Threads of Whitworth Form, Part 1 Sealing Pipe Threads (based on ISO 7) Flanges for Pipes, Valves and Fittings Bolts, Stud Bolts and Nuts for Flanges and Other High and Low Temperature Applications Plumbing Code of Australia Pressure Piping Polyethylene (PE) Pipes for Pressure Applications Polyethylene (PE) compounds for pressure pipes and fittings Part 5: Lining of Equipment with Polymeric Materials for the Process Industries (Rubber Lining) Testing of Valves Line Pipe Pipe, Steel, Black and Hot Dipped, Zinc Coated, Welded and Seamless Forgings, Carbon Steel for Piping Components Carbon Steel Forgings for General Purpose Pipe Forged or Rolled Alloy Steel Pipe Flanges, Forged Fittings and Valves and Parts for High Temperature Service Alloy Steel and Stainless Steel Bolting. Services
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Materials for High Temperature
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ASTM A194 ASTM A216 ASTM A234 ASTM A312 ASTM A403 ASTM A536 ASME B16.5 ASME B16.9 ASME B16.11 ASME B16.25 ASME B31.3 ASME B36.10 ASME B36.19 ANSI B2.1 ANSI/ASME B16.5 ANSI/ASME B16.9
Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Services Steel Castings, Carbon, Suitable for Fusion Welding for High Temperature Services Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Seamless and Welded Austenitic Stainless Steel Pipe Wrought Austenitic Stainless Steel Piping Fittings Ductile Castings Pipe Flanges and Flanged Fittings Factory-Made Wrought Steel Butt Welding Fittings Forged Steel Fittings, Socket Welding and Threaded Butt Welding Ends Process Piping Welded and Seamless Wrought Steel Pipe Stainless Steel Pipe American Standard Taper Pipe Thread, NPT Steel Pipe Flanges and Flanged Fittings 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 DIN 8077 BS 6374 ASTM D2239 Pipe Threads where Pressure Tight Joints are Made on the Threads. Part 1: Dimensions, tolerances and designation Pipes of Polypropylene (PP) Dimensions Pipes of Polypropylene (PP) General Quality Requirements Standard Specification for Polyethylene (PE) Plastic Pipe (S.D.D.R-PR) Based on Controlled Inside Diameter Standard Specification for Polyethylene (PE) plastic tubing Standard Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on Controlled Outside Diameter. Standard Specification for Polyethylene (PE) Plastic Pipe (S.D.D.R-PR) Based on Outside Diameter
ASTM D2737 ASTM D3035
ASTM F714
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3.
ABBREVIATIONS ANSI API AS ASME ASTM BE BS BSP BW CS DN EFW EPDM ERW FCAW FF GR GRES GTAW HDPE ID ISO LR MMA NB NPS OD P&ID PE PN PP PTFE RF Sch SMLS SO American National Standards Institute American Petroleum Institute Australian Standards American Society of Mechanical Engineers American Society of Testing and Materials Bevel End British Standard British Standard Pipe Thread Butt Weld Carbon Steel Nominal Diameter (Number) Electro Fusion Welded Ethylene Propylene Diene Modified Electric Resistance Welded Flux Core Arc Welding Flat Face or Flange Face Grade GR Engineering Services Limited Gas Tungsten Arc Welding High Density Polyethylene Inside Diameter (number) International Standards Organisation Long Radius Manual Metal Arc Nominal Bore (Number) Nominal Pipe Size (Number) Outside Diameter (Number) Piping and Instrumentation Diagram Polyethylene Nominal Pressure (Number) Polypropylene Polytetrafluoroethylene (Teflon) Raised Face Schedule Seamless Slip On
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SS Std Wt TIG UNS WN 4.
Stainless Steel Standard Weight Tungsten Inert Gas Unified Numbering System for Metals and Alloys Weld Neck
RELATED DOCUMENTS Technical Specifications related to this document are: TS15 Surface Treatment.
This document is linked to the following GRES Standard Drawings: 5. 5.1 Piping and Instrumentation Symbols. Small Pipe 'Site Run' Supports. Piping Details. Instrumentation Details. Valve Identification. Typical Rubber Lining Details. Warman Pump Matching Flange Details.
DESIGN DETAILS Pipework All materials, design and fabrication for pipes, fittings, valves and ancillary items for pressure piping systems shall be in accordance with ASME B36.10 and this specification unless noted otherwise stated 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 for each 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 accordance with AMSE B36.10 and the wall thickness calculations shall be based on the internal design pressure, 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 equipment is specified with connections of the sizes listed above, connections shall be made with suitable swages 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 Pipe Size (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 shall be 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 each individual piping specification. Reducing tees are a preferred branch connection. Where pipe to pipe branch connections are used, the reinforcement requirement shall be provided in accordance with 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 thermal efficiency 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, B16.5 and B16.25 respectively. Threads shall be NPT NPT - American Standard Pipe Thread Taper Threads per Inch TPI - pitch 11-1/2 8 8 8 8 8 8 8 8 8 8 8 8 Approximat e Length of Thread (inches) 1 1 1/2 1 1/2 1 5/8 1 5/8 1 3/4 1 3/4 1 7/8 2 2 1/8
1)
Pipe Size (inches)
2" 2-1/2" 3" 3-1/2" 4" 4 1/2" 5" 6" 8" 10" 12" 14" 16"
Approximate Nominal Approximat Total thread Outside Pipe Makeup, e Number Diameter of Threads Hand and OD to be Cut Wrench (inches) (inches) 11 5/8 2.375 12 7/8 2.875 12 1 3.500 13 1 1/16 4.000 13 1 1/16 4.500 5.000 14 1 3/16 5.563 14 1 3/16 6.625 15 1 5/16 8.625 16 1 1/2 10.750 17 1 5/8 12.750 14.000 16.000
Tap Drill (inches)
2-7/32 2-5/8 3-1/4 3-3/4 4-1/4 4-3/4 5-9/32 6-11/32
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5.4 5.4.1
Painting and Service Identification Piping to be Coated On completion of fabrication and prior to installation, piping spools shall be surface protected in accordance 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 design drawings. 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 areas are 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 coding and flow direction indicators Colour coding shall be applied either by bands of colour or by full colouring of the pipe in accordance with the code detailed in Table 5.1. Colour coded flow indicators shall not be less than 375 mm long. All identification markings shall be 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 access point to the pipe in question. Hazardous fluid identification shall be provided in accordance with Table 5.2. Coding shall comprise a 75 mm wide band with diagonal black and yellow strips of equal width for all services greater 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 to be used shall be those listed in Table 5.2 Service Line Description. The Colour of the words shall be 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 Colour Green Silver Grey Brown Yellow-Ochre Violet Light Blue Black Safety Red Safety Yellow Light Orange White Middle Blue Table 5.1 Service Line Description Acid HCL Acid Spent Barren Carbon Barren Liquor Bore Water Caustic Collector (generic) / Promoter Xanthates (SEX) (PAX) Aerophine Thio Larbamates Mercaptans Copper Sulphate Cooling Water Return Cooling Water Supply Cyanide Depressant (generic) Guar. CMC SMBS Diesel (distillate) Electrolyte Solution COL CUS CWR CWS CY DEP DEP DEP DEP FO EL COL Line Prefix AC AS BC BL BW CA COL Jade Silver Grey Golden Tan Sand Lilac Aqua Black Signal Red Golden Yellow Orange Off White Mid Blue
AS2700 Colour Code G21 N24 X53 Y44 P23 B25 N61 R13 Y14 X15 Y35 B15
Pipeline Identification Colours Line Specification 10 10 02, 07 04, 07 04,06,07 07, 08 04,07 04,06, 07 04,07 04,07 04,07 06,07 04 04 07, 08 04,07 04,07 04,07 04,07 04, 08 06 Service Pressure kPa 400 300 400 600 400 600 400 400 400 400 400 400 400 400 600 400 400 400 400 300 600 Hazardous ID Requirement Yes Yes No No No Yes Yes Yes Yes Yes Yes Yes No No Yes No No No No Yes No Colour Coding AS 2700 P23 P23 P23 P23 P23 P23 N61 N61 N61 N61 N61 P23 G21 G21 P23 N61 N61 N61 N61 X53 P23 Lilac Lilac Lilac Lilac Lilac Lilac Black Black Black Black Black Lilac Jade Jade Lilac Black Black Black Black Golden Tan Lilac
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Service Line Description Eduction Water Eluate Solution Fire Water Flocculant Fresh Water Frother (generic) MIBC Teric Interfroths Dowfroths Gland Water Gravity Water High Pressure Air Hose Down Process Water Instrument Air Lime Slurry Liquefied Petroleum Gas Loaded Carbon Low Pressure Air Lube Oil Medium Pressure Air Oxygen Potable Water Pregnant Liquor Process Slurry Process Water Raw Water Raw Water Filtered Sodium Sulphate Strip Solution Sump Discharge Tailings Slurry Thermal Oil
Line Prefix EW EL FW FL WF FR Fr Fr Fr Fr GW GRW HPA
Line Specification 03,04 06 04, 07 04, 07 04, 05, 07 04,07 04,07 04,07 04,07 04,07 04, 05 04, 07 05, 07
Service Pressure kPa 600 600 600 400 600 400 400 400 400 400 600-2500 600 700 400 700 400 140 400 200 300 500 1000 600 600 600 600 600 600 600 600 400 600-1400 600
Hazardous ID Requirement No No No No No Yes Yes Yes Yes Yes No No No No No No Yes Yes No Yes No Yes No No No No No No No No No No Yes
Colour Coding AS 2700 G21 P23 R13 P23 G21 P23 P23 P23 P23 P23 G21 G21 B25 G21 B25 N61 Y44 P23 B25 X53 B25 Y44 B15 P23 N61 G21 G21 G21 P23 P23 N61 N61 X53 Jade Lilac Signal Red Lilac Jade Lilac Lilac Lilac Lilac Lilac Jade Jade Aqua Jade Aqua Black Sand Lilac Aqua Golden Tan Aqua Sand Mid Blue Lilac Black Jade Jade Jade Lilac Lilac Black Black Golden Tan
HDPW 03, 04, 05, 07 IA LY LPG LC LPA LO MPA OX POT PL PS PW RW RWF NAS SS SU TS TO 05 02,07 04, 08 02, 07 04,05 04 05, 04, 06 05, 07 06 01, 07 03,04,07 03, 04, 05, 07 04,05,07 06,07 04, 06, 07 03, 07 01,07 04,
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Service Line Description Treated Water Vacuum Vents Waste Water Table 5.2
Line Prefix TW VA V WW
Line Specification 05,07 04 04, 04,07
Service Pressure kPa 600 Atmos 400
Hazardous ID Requirement No Yes No No
Colour Coding AS 2700 G21 B25 N61 Jade Aqua Black
Piping Specification, Hazardous Identification and Piping Color Schedule
Table 5.2 lists a number of common examples of line fluids and line specifications with their line prefix code, hazardous identification requirements and colour code. 5.5 Line Numbering Pipelines indicated on engineering flowsheets, piping drawings and line lists are identified by line numbers. 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: Individual Number: Line Specification: Assigned Line Number: eg. PS (Process Slurry) eg. 031 (consecutive three digit numbers for each service) eg. 4 or 7 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 pipeline and at each equipment connection. Line numbers have three digits and numbers commence at 001 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 pipe external surface for thermal or personnel protection purposes respectively. Lines so designated shall 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) and Polypropylene (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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Carbon Steel NPS (in)

1 3
Carbon Steel DN (mm) 15 20 25 32 40 50 80 100 125 150 200 250 300 350 400 450 500 600 750 800 900 1000 1050
Stainless Steel DN (mm) 15 20 25 32 40 50 80 100 125 150 200 250 300 350 400 450 500 600 750 800 900 1000 1050
PVC DN (mm) 15 20 25 32 40 50 80 100 125 150 200 250 300 -
PE IPS (in)
PE IPS (mm) 12.7 19.1 25.4 31.8 38.1 50.8 76.2 101.6 141.3 168.3 219.1 273.1 323.9 355,.6 406.4 457.2 508.0 609.6 762.0 812.8 914.4 1066.8
/2 /4
1 1 /4 1 /2 2 3 4 5 6 8 10 12 14 16 18 20 24 30 32 36 40 42
1 1
1 1 /4 1 /2 2 3 4 5 6 8 10 12 14 16 18 20 24 30 32 36 40 42
1 1
NPS: DN: I.P.S:
Nominal Pipe Size (imperial measurement), ANSI term. Nominal Diameter (metric measurement), SI term. Iron Pipe Size as measured for PE and PP pipe (Imperial).
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5.7 5.7.1
Piping Material Specification Selection of Piping Material The Piping Material Specifications detailed in Section 6.0, define the piping materials that shall be used for each type of service. Table 5.2 indicates the Line Specification that is required for a particular type of service.
5.8 5.8.1
Valves Standard Valve Numbering System Each valve shall be identified on P&IDs and piping drawings by a specific valve number. An example of a valve number and an explanation of the format and the codes used to develop the valve number has been provided below. 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
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 the various design parameters that identify the required valve. Legends for the various identifying codes for the standard valve types are listed in the following sections. 5.8.2 Standard Valve Descriptions and Codes For ease of identification, this specification has assigned codes to a number of standard valve types. The following lists define the codes assigned for this specification and relate the codes to a number 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
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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, Soft Rubber 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 Wetted Parts. Series 4 Knife Type, Stainless Steel Body, Through Port, EPDM Seat, Stainless Steel Wetted 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 Valves Series 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, Fire Safe. 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 PTFE Seal, 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 construction and the physical design parameters for a number of standard pipeline types. The Pipeline Material Specifications selected for a particular duty must be appropriate for the pipeline service listed in Table 5.1 and at the head of each data sheet.
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Piping Material Specification 1

Service: Design Conditions: Material: Size Pipe: 2 NB (DN 50) and above Fittings: Elbows 2 NB (DN 50) and above. Tees and Reducers Flanges: 2 NB (DN 50) and above Lining: Note 3 Testing: All Bolting: All Bolts: Hexagonal head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Valves: Series 2 (DN 50) 4 (100) Series 6 NB (DN 150) and above Ball (V4) Butterfly (V2) Check (V7) Gate (V3) Knifegate (V3) 3, 4, 5 or 6 3, 4, 5 or 6 (ASTM, A306 Grade A) (ASTM A306, Grade A) Rubber Lining to be spark tested. Piping to be Hydrostatic tested. BS 6374 Part 5 AS 4041 Natural Rubber, Shore Hardness 35 60. Refer to notes for BS 6374 thickness. Carbon Steel. Full Face socket weld. ANSI 150 Black Carbon Steel Butt Weld. Std Wt, to be rubber lined, 3 x ASTM A 234 - WPB diameters unless noted otherwise on the design drawings. Black Carbon Steel Butt Weld. Std Wt, to be rubber lined ASTM A 234 - WPB Std Wt. Carbon Steel ERW or Seamless Sch 40 Plain ends A106 B API 5L Gr B ASTM A53 Gr B Process Slurry (PS) Temperature (Max): Operating / Test Pressure: Carbon Steel ASME B36.10 Sched 40 Description Tailings Slurry (TS) 0 - 80 degrees Celsius 1000 kPa Flange Rating: Corrosion Allowance: ANSI 150 Nil Standard
Code Requirements:
Notes: 1. 2. 3. Straight runs of pipe shall be fabricated in standard flanged 6000 mm long, face to face. This is not to be exceeded. Refer to design detail drawings for face to face dimensions. If raised face flanging is used, please ensure the raise face is removed prior to lining. All natural rubber lining to be 6 mm thick unless noted otherwise on the design drawings. Rubber type should be that specified on the design drawings or GRES approval sought for an alternative supply. For details of lining @ Flanges, joints etc, refer to GRES Standard Drawings, referred to on the design drawings. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. Gaskets normally not required for Rubber lined joints. However where joints are frequently dismantled use 1.5 mm thick PTFE gaskets.
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4. 5.
6.
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7. 8. 9.
All spooling should have flanged ends capped for transport and to help prevent damage from ultra violet radiation prior to erection. Refer to valve selection chart for full valve descriptions. Polyethylene spacer rings may be required for butterfly valves to assist in valve operation.
Branch Connection Table Nominal size. 50 2 600 500 450 400 350 300 250 200 150 100 80 65 50 NB 24 20 18 16 14 12 10 8 6 4 3 2 2 NPS S S S S S S S S S B B B A 65 2 S S S S S S S S S B B A 80 3 S S S S S S S B B B A 100 4 S S S S S S B B B A 150 6 S S S B B B B B A 200 8 S B B B B B B A A: B: C: D: E: F: S: Equal Tee, Flanged. Reducing Tee, Flanged. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening. Flanged. 250 10 B B B B B B A 300 12 B B B B B A 350 14 B B B B A 400 16 B B B A 450 18 B B A 500 20 B A 600 24 A NB NPS
Table Notes: 1. 2. 3. All Stub-in connections shall be checked in accordance with the pressure design requirements of ANSI/ASME 31.3 and reinforcement (stiffening) shall be provided where necessary. NB: Nominal Bore Size. Measured in Metric. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard.)
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Service: Design Conditions: Material: Size Pipe: 2 (DN 50) and above Fittings: Pull Bends Y Piece Reducers Flanges: 2 (DN 50) and above Couplings: All Gaskets: All 1.5 mm thick non asbestos fibre, full face. Klingersil C-4430 or approved equivalent. Alternatively - Kingerlastic 1.5 mm thick EPDM, full face. Bolts: Hexagonal Head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Valves: Series DN 50 - 100 Ball (V4) Butterfly (V2) Check (V7) BS 3663 Victaulic couplings to be used at each change of direction. EPDM sealing rings. BS EN 10241 Black Carbon Steel. Full Face socket weld. ANSI 150 Fabricated from ERW Std Wt, bends pulled to 3 x diameter c/w victaulic shouldered ends. Black Carbon Steel. Std Wt c/w victaulic shouldered ends. API 5L Gr B ASTM A 234 WPB Black Carbon Steel. Medium Weight. Shouldered Victaulic Ends. ASME B36.10 Sched 404 Barren Carbon (BC) Temperature (Max): Operating / Test Pressure: Carbon Steel ASME B16.5 Description Lime Slurry (LY) 1000 kPa Flange Rating: Corrosion Allowance: ANSI 150 1 mm Standard Loaded Carbon (LC)
0 - 80 degrees Celsius
Code Requirements:
Bolting: All AS1111, Gr 4.6 (ASTM, A306 Grade A) AS 1112, Gr 4.6 (ASTM A306, Grade A) Diaphragm (V1) 2 or 5 Knifegate (V3)
Notes: 1. 2. Refer to valve selection chart for full valve descriptions. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. Pull Bends and radius shaped Tees are to be used in all change of directions, this so not to damage the carbon particles in the slurry solution.
3.
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Branch Connection Table Nominal size. 15 300 250 200 150 100 80 65 50 40 32 25 20 15 NB 12 10 8 6 4 3 2 2 1 1 1 NPS S S B B B B A S S B B B A S S B B A S S S S A: B: C: D: E: F: S: Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection c/w 3 D pull bend radius. S S S S S S 20 25 1 32 1 40 1 50 2 65 2 80 3 100 4 150 6 200 8 250 10 300 12 NB NPS
Table Notes: 1. 2. 3. All Stub-in connections shall be checked in accordance with the pressure design requirements of AS 4041 and reinforcement (stiffening) shall be provided where necessary. NB: Nominal Bore Size. Measured in Metric. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard.)
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Service: Design Conditions: Material: Size Pipe: 1/2 to 2 DN 15 - 50 DN 65 - 150 8 to 16 (DN 200 350) Fittings: to 2 (DN 15 50) DN 65 and above Flanges: to 2 (DN 15 50) DN 65 and above Couplings: to 2 (DN 15 50) DN 65 - 350 Gaskets: All 1.5 mm thick non asbestos fibre, full face. Klingersil C-4430 or approved equivalent. Alternatively - Kingerlastic 1.5 mm thick EPDM, full face. Bolts: Hexagonal Head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Valves: Series 2 (DN 15 50) Series 2 (DN 65) and above Ball (V4) 1 or 2 3 or 6 Butterfly (V2) 1 1 Check (V7) 2 or 8 BS 3663 Black Carbon Steel. Viton Seat. Victaulic Ring Type A c/w Galvanised Victaulic Couplings. Sealing Ring EDPM. BS EN 10241 Black Carbon Steel. Full Face, threaded to NPT. Black Carbon Steel. Full Face socket weld. ASME B16.5, ANSI 150, ANSI B2.1 ASME B16.5, ANSI 150 Black Carbon Steel. NPT Thread. Black Carbon Steel. Std Wt. c/w Victaulic Shouldered Ends. BS1740, BS1722 Black Carbon Steel. Medium Weight. Screwed and Socketed. Black Carbon Steel. Medium Weight. Shouldered Victaulic Ends. Std Wt. Carbon Steel ERW. Shouldered Victaulic Ends. API 5L Gr B Process Water (PW) Temperature (Max): Operating / Test Pressure: Carbon ASME B36.10 Description Raw Water (RW) Fire Water (FW) Sump Discharge (SU) Eduction Water (EW)
Hose Down Water - Process Water (HDPW) 1000 kPa
50 180 degrees Celsius Flange Rating: Corrosion Allowance: ANSI 150 1 mm Standard
Code Requirements:
Bolting: All AS1111, Gr 4.6 (ASTM, A306 Grade A) AS 1112, Gr 4.6 (ASTM A306, Grade A) Diaphragm (V1) 1 1 Knifegate (V3)
Notes: 1. 2. 3. Threads shall be sealed using Loctite 567 (Thread Paste) or Teflon thread sealing tape (Thread Tape) or an approved equivalent sealing compound. Refer to valve selection chart for full valve descriptions. Use of barrel unions up-to and including 2 (50 NB) except where connected to flanged components.
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4. 5.
Provide barrel unions or flanged connections at appropriate distances and at change of direction to allow or where required to allow for disassembly. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread.
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Branch Connection Table Nominal size. 15 300 250 200 150 100 80 65 50 40 32 25 20 15 NB 12 10 8 6 4 3 2 2 1 1 1 NPS C C C C C C C B B B B B A 20 C C C C C C C B B B B A 25 1 C C C C C C C B B B A 32 1 C C C C C C C B B A 40 1 C C C C C C C B A 50 2 C C C C C C B A A: B: C: D: E: F: S: Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening. 65 2 S S S S S B A 80 3 S S S S B A 100 4 S S S B A 150 6 S B B A 200 8 B B A 250 10 B A 300 12 A NB NPS
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Service: Process Water (PW) Barren Liquor (BL) Flocculant (FL) Oxygen (OX) Gland Water (GW) Raw Water (RW) Fresh Water (WF) Gravity Water (GRW) Diesel (Distillate)(FO) Vents (V) Fire Water (FW) Collectors (COL) Lube Oil (LO) Waste Water (WW) Frother (FR) Cooling Water Return (CWR) Liquefied Petroleum Gas (LPG) Low Pressure Air (LPA) 0 - 80 degrees Celsius 1000 kPa Flange Rating: Corrosion Allowance: ANSI 150 Nil Standard ASME B36.10 ASME B36.10 API 5L Gr B ANSI B2.1 Bore Water (BW) Vacuum (VA) Thermal Oil (TO) Depressant (DEP)
Cooling Water Supply (CWS) Hose Down Water - Process Water (HDPW) Raw Water Filtered (RWF) Design Conditions: Material: Size Pipe: 2 (DN 15 50) 2 6 (DN 65 150) 8 (DN 200) and above Fittings: DN 15 50 DN 65 and above Flanges: DN 15 50 DN 65 and above Couplings: DN 15 50 Gaskets: All Black Carbon Steel. Viton Seat. Black Carbon Steel. NPT Thread. Black Carbon Steel. Std Wt. Butt Weld Temperature (Max): Operating / Test Pressure: Carbon Steel ASME B36.10 Description
Code Requirements:
Black Carbon Steel. Medium Weight. Screwed and Socketed. Black Carbon Steel. Medium Weight. Butt Weld. Std Wt. Carbon Steel ERW. Butt Weld.
Black Carbon Steel. Full Face threaded to BSP. Black Carbon Steel. Full Face Slip On.
ASME B16.5, ANSI 150 ASME B16.5, ANSI 150 BS EN 10241 BS 3663
1.5 mm thick non asbestos fibre, full face. Klingersil C-4430 or approved equivalent. Alternatively - Kingerlastic 1.5 mm thick EPDM, full face. Bolts: Hexagonal Head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized.
Bolting: All AS1111, Gr 4.6 (ASTM, A306 Grade A) AS 1112, Gr 4.6 (ASTM A306, Grade A) Diaphragm (V1) 1 or 2 1 or 2 Knifegate (V3)
Valves: Series 2(DN 15 50) Series 2 (DN 65) and above
Ball (V4) 1, 2 or 3 3 or 4
Butterfly (V2) 1 1
Check (V7) 2 or 8 2, 4 or 5
Notes: 1. Threads shall be sealed using Loctite 567 (Thread Paste) or Teflon thread sealing tape (Thread Tape) or an approved equivalent sealing compound.
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2. 3. 4. 5.
Refer to valve selection chart for full valve descriptions. Use of barrel unions up-to and including 2 (50 NB) except where connected to flanged components. Provide barrel unions or flanged connections at appropriate distances and at change of direction to allow or where required to allow for disassembly. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. LPG line up to 1 (25NB) only.
Branch Connection Table Nominal size. 15 300 250 200 150 100 80 65 50 40 32 25 20 15 NB 12 10 8 6 4 3 2 2 1 1 1 NPS C C C C C C C C C B B B A 20 C C C C C C C C C B B A 25 1 C C C C C C C B B B A 32 1 C C C C C C C B B A 40 1 C C C C C C C B A 50 2 C C C C C C B A A: B: C: D: E: F: S: Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening. 65 2 S S S S S B A 80 3 S S S S B A 100 4 S S S B A 150 6 S B B A 200 8 B B A 250 10 B A 300 12 A NB NPS
6.
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Service: Low Pressure Air (LPA) Fire Water (FW) High Pressure Air (HPA), Hose Down Water Process Water (HDPW) Design Conditions: Material: Size Pipe: DN 15 - 50 DN 65 - 150 DN 200 and above Fittings: DN 15 - 50 DN 65 and above Flanges: to 2 (DN15 50) 2 (DN 65) and above Couplings: tp 2(DN 15 50) Gaskets: All 1.5 mm thick non asbestos fibre, full face. Klingersil C-4430 or approved equivalent. Alternatively - Kingerlastic 1.5 mm thick EPDM, full face. Bolts: Hexagonal Head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Valves: Series to 2 (DN 15 50) Series 2 (DN 65) and above Ball (V4) 1, 2 or 3 3 or 4 Butterfly (V2) 1 1 Check (V7) 2 or 8 2, 4 or 5 BS 3663 Zinc-Coated Carbon Steel. Viton Seat. BS EN 10241 Galvanised Carbon Steel. Full Face, threaded to BSP. Galvanised Carbon Steel. Full Face Slip On. ASME B16.5, ANSI 150 ASME B16.5, ANSI 150 Galvanised Carbon Steel. NPT Thread. Galvanised Carbon Steel. Std Wt c/w Rolled Grooved Victaulic Ends. ANSI B2.1 Galvanised Carbon Steel. Medium Weight. Screwed and Socketed. Galvanised Carbon Steel, Medium Weight, Plain Ended or Rolled Grooved Victaulic Ends. Std Wt. Carbon Steel ERW. Hot Dipped Galvanised. 1. 2. API 5L Gr B AS 1074 AS 1074 Temperature (Max): Operating / Test Pressure: Galvanised Carbon Steel ASME B36.10 Description 0 - 80 degrees Celsius 1000 kPa Flange Rating: Corrosion Allowance: ANSI 150 Nil Standard Instrument Air (IA) Fresh Water (WF) Raw Water (RW) Treated Water (TW) Medium Pressure Air (MPA), Gland Water (GW)
Code Requirements:
Bolting: All AS1111, Gr 4.6 (ASTM, A306 Grade A) AS 1112, Gr 4.6 (ASTM A306, Grade A) Diaphragm (V1) Knifegate (V3) 2 2
Notes: 1. 2. 3. Threads shall be sealed using Loctite 567 (Thread Paste) or Teflon thread sealing tape (Thread Tape) or an approved equivalent sealing compound. Refer to valve selection chart for full valve descriptions. Use of barrel unions up-to and including 2 (50 NB) except where connected to flanged components.
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4. 5. 6.
Provide barrel unions or flanged connections at appropriate distances and at change of direction to allow or where required to allow for disassembly. All nominated water services (WR, GW, FW, POT and HDPW) are only for line sizes up-to and including 2 (50 NB) only. For lines above this refer to pipe specification 3 or 4. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. Not for use on drinking water service. AS 3500 precludes the use of galvanized pipe in drinking water service.
Branch Connection Table
7.
Nominal size.
15
20 C C C C C C C B B B B A
25 1 C C C C C C C B B B A
32 1 C C C C C C C B B A
40 1 C C C C C C C B A
50 2 C C C C C C B A
65 2 S S S S S B A
80 3 S S S S B A
100 4 S S S B A
150 6 S B B A
200 8 B B A
250 10 B A
300 12 A
NB NPS
300 250 200 150 100 80 65 50 40 32 25 20 15 NB
12 10 8 6 4 3 2 2 1 1 1 NPS
C C C C C C C B B B B B A
A: B: C: D: E: F: S:
Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening.
Table Notes: 1. 2. 3. All Stub-in connections shall be checked in accordance with the pressure design requirements of AS 4041 and reinforcement (stiffening) shall be provided where necessary. NB: Nominal Bore Size. Measured in Metric. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard)
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Service: Oxygen (OX) Cyanide (CY) Copper Sulphate (CUS) Design Conditions: Material: Size Pipe: to 2(DN 15 50) 2 8 (DN 65 200) Fittings: 2 DN 15 - 50 2 tp 8 DN 65 and 200 Flanges: 2 DN 15 - 50 2 (DN 65) and above Couplings: DN 15 - 50 Gaskets: All 1.5 mm thick non asbestos fibre, full face. Klingersil C-4430 or approved equivalent. Alternatively - Kingerlastic 1.5 mm thick EPDM, full face. Bolts: Hexagonal Head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Special Application Valves: Series 2(DN 15 50) Series 2 (DN 65) and above SS Bolts, Studs and Nuts. Ball (V4) 2 or 3 3 Butterfly (V2) 2, 3 or 4 2, 3 or 4 Check (V7) 5 or 8 8 BS 3663 Stainless Steel. Viton Seat. BS EN 10241 Stainless Steel. Full Face, threaded to NPT. Stainless Steel. Full Face Slip On. ASME B16.5, ANSI 150 ASME B16.5, ANSI 150 Forged, Class 3000, BSP or Socket Weld 3000# Butt Welded, Schedule 10S ASTM A182 ASTM A403M Stainless Steel, Gr 316L, Schedule 40S, SMLS Plain ends. Stainless Steel, Gr 316L, Schedule 10S, ERW, Bevel ends. ASTM A312 GR TP 306L ASTM A312 GR TP 306L Temperature (Max): Operating Pressure: Stainless Steel 316 L ASTM A312 Description Eluate Solution (EL) Caustic (CA) Collectors (COL) 120 degrees Celsius 500 kPa max Test Pressure: Flange Rating: Corrosion Allowance: 1000 kPa ANSI 150 1 mm Standard Pregnant Liquor (PL) Sodium Sulphate (NAS) Strip Solution (SS) Bore Water (BW)
Code Requirements:
Bolting: General Application AS1111, Gr 4.6 (ASTM, A306 Grade A) AS 1112, Gr 4.6 (ASTM A306, Grade A) ASTM A 193 GR B8 ASTM A 194 GR8 Gate (V3) Knifegate (V3)
Notes: 1. 2. 3. Threads shall be sealed using Loctite 567 (Thread Paste) or Teflon thread sealing tape (Thread Tape) or an approved equivalent sealing compound. Refer to valve selection chart for full valve descriptions. Use of Stainless Steel barrel unions up-to and including 2 (50 NB) except where connected to flanged components.
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4. 5. 6.
Provide barrel unions or flanged connections at appropriate distances and at change of direction to allow or where required to allow for disassembly. Galvanised steel, Stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. The use of Pipe specification 6, for any service where the designated route is in area where onerous conditions exist. An example of this is on top of Leach and Adsorption Tanks, below the top of platform steelwork. 1.5 mm thick non asbestos fibre, full face. Klingersil C-8200 or approved equivalent for Eluate, Strip Solutions and Pregnant Liquor, the other services can be Klingersil C-4430 or approved equivalent.
7.
Branch Connection Table Nominal size. 15 300 250 200 150 100 80 65 50 40 32 25 20 15 NB 12 10 8 6 4 3 2 2 1 1 1 NPS C C C C C B B B B B A C C C C C B B B B A C C C C C B B B A C C C C C B B A C C C C C B A C C C C B A A: B: C: D: E: F: S: Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening. S S S B A S S B A S B A B A A 20 25 1 32 1 40 1 50 2 65 2 80 3 100 4 150 6 200 8 250 10 300 12 NB NPS
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Service: Process Slurry (PS) Flocculant (FL) Raw Water (RW) Fire Water - Buried (FW) Frother (FR) Sodium Sulphate (NAS) Sump Discharge (SU) Cyanide (CY) Bore Water (BW) Collector (COL) Gravity Water (GRW) Treated Water (TW) Barren Carbon (BL) Caustic (CA) Fresh Water (WF) Copper Sulphate (CUS) Loaded Carbon (LC) Waste Water (WW) High Pressure Air Buried (HPA) Barren Liquor (BL) Process Water (PW) Potable Water (POT) Depressant (DEP) Lime Supply (LY)
Tailings Slurry - Refer Design - PON Rating (TS) Hose Down Water Process Water (HDPW) Design Conditions: Material: Size Pipe: -6 IPS (20 160 OD) 4 24 IPS (110 630 OD) Fittings: 2 (20 75 OD) 2 24 (50 630 OD) Temperature (Max): Operating / Test Pressure: ASTM D2239 Description
20 degrees Celsius, 40 degrees Celsius, 60 degrees Celsius. 1000 kPa @ 20 C, 750 kPa @ 40 C, 560 kPa @ 60 C. Flange Rating: Corrosion Allowance: ANSI 150 Nil Standard ASTM D2239 ASTM D2239
High Density Polyethylene PE 4710
Code Requirements:
High Density Polyethylene PE 4710 DR 17 (125psi): Continuous Coil. High Density Polyethylene PE 4710 DR 17 (125psi): Straight Lengths. PE, Plasson or Equivalent Type Compression Fittings. PE, Butt Fusion Weld Connections, Stub Ends, Short Radius Elbows, Sweep Bends, Reducers, Fabricated Tees and Y Sections. Galvanised Carbon Steel. Full Face, threaded to BSP (Plasson male adaptors). Polyethylene Stub Ends c/w Galvanised Carbon Steel Backing Ring. Victaulic Shoulder c/w Galvanised Victaulic Coupling. Refer to Note 6.
AS 4129, ASTM D3139? AS 4129, ASTM D3139?
Flanges: -2 (20 63 OD) 2 24(50 630 OD) Couplings: ASME B16.5, ANSI 150 ASME B16.5, ANSI 150
Gaskets: All Bolting: All Bolts: Hexagonal head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Valves: Series DN 15 - 50 Series DN 65 and above Ball (V4) 1, 2 & 3 & 6 2, 3, 4, 5 & 6 Butterfly (V2) 1 1 Check (V7) 2 or 8 2, 4 or 5 AS1111, Gr 4.6 (ASTM, A306 Grade A) AS 1112, Gr 4.6 (ASTM A306, Grade A) Diaphragm (V1) Knifegate (V3) 1 or 2 1, 2, 3, 4 & 5 4 3, 4, 5 & 6 1.5mm or 3.0mm thick full face. Insertion Rubber. BS 3663, ASTM F477
Notes: 1. PE 4710 DR 17 (125 psi) is the minimum PE piping design class for pressure applications within the process plant.
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2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Diameters nominated are pipe, fitting IPS., (inside nominal bore) Compression fittings shall not be used on any toxic or corrosive fluids. For example Caustic, Cyanide, lime. Nominal pressure rating for all compression fitting used to be PN16.(230psi) Short radius elbows are only to be used on non slurry lines. (Water services etc) All Slurry service lines to have 3 D Sweep Bends with victaulic shoulder couplings for ease of breaking line for maintenance purposes. This also includes Sump Lines. Fabricated Lobster backs not to be used. Pressure ratings shall be reduced with increased temperature in accordance with Manufactures recommendations. Where buried services are installed, insure pipe routes are fully continuous butt weld circuits. Survey to be done prior to backfilling of lines. Fire Water lines (buried) require change in spec a minimum of 200 mm below ground when protruding to the surface. Check design drawings on the designed pressure rating. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. Where bolts are used underground ensure they are completely wrapped with Denso Tape. Where Butterfly Valves are used inline please ensure valve disc will open freely. Site engineer to advise if stub end can be bevelled to suit or poly spacer is required for that application.
Branch Connection Table
12.
Nominal size.
20
25 C C C C C C C B B B B A
32 1 C C C C C C C B B B A
40 1 C C C C C C C B B A
50 1 C C C C C C C B A
63 2 C C C C C C B A
75 2 D D B B B B A
90 3 D D B B B A
110 4 D B B B A
160 6 B B B A
225 8 B B A
280 10 B A
315 12 A
OD NPS
315 280 225 160 110 90 75 63 50 40 32 25 15 OD
12 10 8 6 4 3 2 2 1 1 1 NPS
C C C C C C C B B B B B A
A: B: C: D: E: F: S:
Equal Tee. Reducing Tee. Tapping Saddle - Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening.
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Table Notes: 1. 2. 3. All Stub-in connections shall be checked in accordance with the pressure design requirements of AS 4130 and reinforcement (stiffening) shall be provided where necessary. IPS: Iron Pipe Size. Measured in Imperial, and relates to the nominal internal bore of the pipe.. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard.)
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Service: Design Conditions: Material: Size Pipe: 2 (DN 15 50) 2 (DN 65) and above Fittings: to 2 (DN 15 50) 2 (DN 65) and above Flanges: 2 (DN 15 50) 2 (DN 65) and above Couplings: N/A Gaskets: All Bolting: All Studs or Bolts: Hexagonal head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Ball (V4) 1, 2 & 3 & 6 1, 2, 3 & 6 Butterfly (V2) 1 1 Check (V7) 2&8 2, 5 & 8 ASTM A 193 GR 7 ANSI/ASME B 1.1 ASTM A 194 GR 2H Gate (V3) 1&2 1&2 Knifegate (V3) 1.5 mm thick non asbestos fibre, ring face. Klingersil C-4430 or approved equivalent. ANSI/ASME B 16.21 Black Carbon Steel, Raised face Slip on. Black Carbon Steel, Raised face Slip on. ASTM A 105 ANSI B 16.5 ASTM A 105 ANSI B 16.5 Forged 3000# Black Carbon Steel. Socket Weld. Black Carbon Steel. Std Wt Butt Welded ASTM A 105 ANSI B 16-11 ASTM A 234 ANSI B 16-11 Black Carbon Steel ERW Schedule 80. Black Carbon Steel ERW Schedule 40. API 5L Gr B ANSI B 36.10 API 5L Gr B ANSI B 36.10 Liquified Petroleum Gas (LPG) Temperature (Max): Operating Pressure: Carbon Steel AS 4041 Description Diesel Distillate (DS) Cyanide (CY) Caustic (CA) 1500 kPa Class 150 RF 1 mm Standard
80 degrees Celsius 1000 kPa max Test Pressure: Flange Rating: Corrosion Allowance:
Code Requirements:
Valves: 2(DN 15 50) 2 (DN 65) and above
Notes: 1. 2. 3. 4. Threads shall be sealed using Loctite 567 (Thread Paste) or Teflon thread sealing tape (Thread Tape) or an approved equivalent sealing compound. Refer to valve selection chart for full valve descriptions. Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. All pipe that is buried to be fully wrapped with Denso Tape in accordance with Manufactures Specifications.
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Branch Connection Table Nominal size. 15 300 250 200 150 100 80 65 50 40 32 25 20 15 NB 12 10 8 6 4 3 2 2 1 1 1 NPS C C C C C C C B B B B B A 20 C C C C C C C B B B B A 25 1 C C C C C C C B B B A 32 1 C C C C C C C B B A 40 1 C C C C C C C B A 50 2 C C C C C C B A A: B: C: D: E: F: S: Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening. 65 2 S S S S S B A 80 3 S S S S B A 100 4 S S S B A 150 6 S B B A 200 8 B B A 250 10 B A 300 12 A NB NPS
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Not Used
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Service: Design Conditions: Material: Size Pipe: 20 110 OD Fittings: 20 63 OD 90 110 OD Socket Weld Fusion Jointing. Butt Weld Fusion Connections, Stub Ends, Short Radius Elbows, Sweep Bends, Reducers, Fabricated Tees and Y Sections. DIN 16962 DIN 16962 Grey Polypropylene PN 10. Straight Lengths. DIN 16962 35% Hydrochloric Acid (AC) Temperature (Max): Operating / Test Pressure: Polypropylene PN 10 AS 4041 Description 3% Hydrochloric Acid (AC) Spent Acid (AS)
20 degrees Celsius, 40 degrees Celsius, 60 degrees Celsius. 1000 kPa @ 20 C, 750 kPa @ 40 C, 480 kPa @ 60 C Flange Rating: Corrosion Allowance: Table E 1 mm Standard
Code Requirements:
Flanges: 20 110 OD Pipe Joints: Socket Weld Fusion Jointing and/or Butt Weld Fusion Connections. Gaskets: All Bolting: All Valves: DN 15 - 50 DN 65 and above Bolts: Hexagonal head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. Ball (V4) 4&5 4&5 Butterfly (V2) 4 4 Check (V7) 3, 6 & 7 3, 6 & 7 AS 1111, Gr 4.6 AS 1112, Gr 4.6 Gate (V3) Knifegate (V3) 1.5 mm thick non asbestos fibre, full face. Klingersil C-8200 or approved equivalent. BS 3663 Polypropylene Stub Ends c/w Galvanised Carbon Steel Backing AS 2129 Table E Ring.
Notes: 1. 2. 3. 4. Grey Polypropylene PN10 is the minimum PP piping design class for pressure applications within the process plant. Diameters nominated are pipe, fitting OD. (outside diameter) Pressure ratings shall be reduced with increased temperature in accordance with Manufactures recommendations. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread. Where bolts are used underground ensure they are completely wrapped with Denso Tape. Where Butterfly Valves are used inline please ensure valve disc will open freely. Site engineer to advise if stub end can be bevelled to suit or poly spacer is required for that application.
5.
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Branch Connection Table Nominal size. 20 315 280 225 160 110 90 75 63 50 40 32 25 20 OD 12 10 8 6 4 3 2 2 1 1 1 NPS C C C B B B B B A C C C B B B B A C C C B B B A C C C B B A C C C B A A: B: C: D: E: F: S: Equal Tee. Reducing Fabricated Tee. Tapping Saddle - Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening. C C B A B B A B A A 25 32 1 40 1 50 1 63 2 75 2 90 3 110 4 160 6 225 8 280 10 315 12 OD NPS
Table Notes: 1. 2. 3. All Stub-in connections shall be checked in accordance with the pressure design requirements of AS 4130 and reinforcement (stiffening) shall be provided where necessary. OD: Outside Diameter of Pipe Size. Measured in Metric. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard.)
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Service: Design Conditions: Material: Size Pipe: 2 (DN 15 -150) Galvanised Carbon Steel. Schedule 40 ASTM A53 Gr B, API 5L Gr B ANSI B 36.10 ASTM A 105 ANSI B 16.11 ANSI B1.20.1 ASTM A 234 ANSI B 16.9 ASTM A 105 ANSI B 16.5 High Pressure Air (HPA) Temperature (Max): Operating / Test Pressure: Galvanised Carbon Steel AS 4041 Description 0 - 80 degrees Celsius 1400 kPa Flange Rating: Corrosion Allowance: ANSI 150 Nil Standard
Code Requirements:
Fittings: - 2 (DN 15 50) Galvanised Forged Carbon Steel. 3000#. NPT Thread.
2 6 (DN 65 -150) Flanges: 2 6 (DN 65 -150) Gaskets: All
Galvanised Carbon Steel. Schedule 40. Butt Welded
Galvanised Carbon Steel. Table E. Flat Face. Slip on (Note 1)
1.5 mm thick non asbestos fibre, full face. Klingersil C-4430 or BS 3663 approved equivalent. Alternatively - Kingerlastic 1.5 mm thick EPDM, full face. Bolts: Hexagonal Head, Hot Dipped Galvanized. Nuts: Hexagonal, Hot Dipped Galvanized. AS1111, Gr 4.6 (ASTM, A306 Grade A) AS 1112, Gr 4.6 (ASTM A306, Grade A) Diaphragm (V1) Knifegate (V3)
Bolting: All
Valves:
Ball (V4)
Butterfly (V2)
Check (V7)
Series - 2 (DN 15 1 50) Series 2 6 (DN 65 - 1,3 150) 8
Notes: 1. 2. 3. 4. 5. ANSI Class 150 flanges Fabricated spools shall be hot dip galvanized Threads shall be sealed using Loctite 567 (Thread Paste) or Teflon thread sealing tape (Thread Tape) or an approved equivalent sealing compound. Refer to valve selection chart for full valve descriptions. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread.
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Branch Connection Table Nominal size. 15 300 250 200 150 100 80 65 50 40 32 25 20 15 NB 12 10 8 6 4 3 2 2 1 1 1 NPS C C C C B B B B B A C C C C B B B B A C C C C B B B A C C C C B B A C C C C B A C C C B A A: B: C: D: E: F: S: Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening. S S B A S B A B A A 20 25 1 32 1 40 1 50 2 65 2 80 3 100 4 150 6 200 8 250 10 300 12 NB NPS
Table Notes: 1. 2. 3. All Stub-in connections shall be checked in accordance with the pressure design requirements of AS 4041 and reinforcement (stiffening) shall be provided where necessary. NB: Nominal Bore Size. Measured in Metric. NPS: Nominal Pipe Size. Measured in Imperial. (American Standard)
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Service: Design Conditions: Material: Size Pipe: 1 (DN 15 -40) Carbon Steel. Schedule 80. Socket Welded ASTM A53 Gr B, API 5L Gr B ANSI B 36.10 ASTM A53 Gr B, API 5L Gr B ANSI B 36.10 Process Water (PW) High Pressure Air (HPA) Temperature (Max): Operating / Test Pressure: Carbon Steel ASME B31.3 Description 0 - 80 degrees Celsius 15000 kPa Flange Rating: Corrosion Allowance: Class 900 1 mm Standard
Code Requirements:
2 6 (DN 50 -150)
Carbon Steel. Schedule 80. Butt Welded
Fittings: 1 : (DN 15 40) 2 6 (DN 50 -150) Flanges: 1 6 (DN 25 150) Gaskets: All Bolting: All Valves: Note 1 Studs Nuts Ball (V4) Plug (VS) S S S Check (VS) ASTM A193 Gr B7 ASTM A194 Gr 2H Spiral Wound Type. ANSI B 16.20 Black Carbon Steel. ANSI Class 900.Raised Face. ASTM A 105 ANSI B 16.5 Black Carbon Steel Forged 3000# Carbon Steel. NPT Socket ASTM A 105 Welded. ANSI B 16.11 Carbon Steel. Schedule 80. Butt Welded ASTM A 234 ANSI B 16.9
Series 1 (DN 15 S 40) Series2- 6 (DN 50 S 150)
Notes: 1. Galvanised steel, Black steel or stainless steel bolts where used are to be coated with Bostik Never-seez, Loctite 771 Anti-seize or an approved equivalent. Ensure any excess is wiped clear of thread.
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Branch Connection Table Nominal size. 15 20 25 1 32 1 40 1 50 2 65 2 80 3 100 4 150 6
150 100 80 65 50 40 32 25 20 15 NB
6 4 3 2 2 1 1 1 NPS
F F F F F F B B B A
F F F F F F B B A
F F F F B B B A
F F F F B B A
F F F F B A
F F F B A
S S B A
S B A
B A
A: B: C: D: E: F: S:
Equal Tee. Reducing Tee. Threadolet. Reducing Tee and Concentric Reducer. Equal Tee and Concentric Reducer. Sockolet. Stub-in, pipe to pipe connection without additional stiffening.
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7. 7.1
FABRICATION / MANUFACTURE General Work shall be carried out in accordance with ANSI/ASME B31.3 and good engineering practice by qualified trades persons. The work shall be properly documented and records prepared and continuously updated as necessary, for proper execution and control of fabrication. All materials shall be in accordance with all parts of this specification and the piping specification data sheets specified.
7.2 7.2.1
Shop Fabrication Workshop Requirements Adequate under cover workshop facilities shall be provided to ensure a safe, efficient and continuous preparation of piping spools for welding and assembly. Surface preparation should be undertaken 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 all facets of pipe fabrication. The documentation to be prepared will include but not be limited to the following. 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 of the contractor to verify the accuracy of any given dimensions and make due allowance for site closures to cover the eventuality of site obstructions and dimensional errors of a minor 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 equipment then 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 the design 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 butt welding with the mating spool and with a nominated amount of "green" left on the pipe, for site trimming. 3000 lb sockolets or weldolets to A105 grade II shall be used on connections of 50 mm and under. No screwed sockets shall be used unless permission has been granted by the 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 its quality. Where specified, items shall be heat treated after forming is completed. Only where specified on design drawings a segmented bend or "lobster back" may be used. Segmented bends shall be manufactured by butt welding together segments of pipe shaped to produce the required bend. Wherever possible the segments shall be taken from the same length of pipe. Each segment of a segmented bend shall not exceed 30 degrees, unless specified or agreed to by the company representative. Formed or segmented bends shall be manufactured without distortion of the cross section of 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 in accordance with AWS DIO. Manual arc welding of butt and branch joints shall be carried out in accordance with AWS DIO. Welder qualifications shall conform to AWS ATF. The contractor is to provide documentation detailing welding procedures and the format of the 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 site should be equivalent to those noted below: a. Procedure for Slip On (SO) flanges and spinning flange backing rings shall be: Run b. 1.6 mm FLAW wire ESAB 71 T or equivalent.
Procedure for butt weld fittings GTAW/FLAW: Root Run 2.4 mm GTAW solid wire LW1. FLAW wire ESAB 71 T or equivalent. 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. FLAW wire ESAB 71 T or equivalent. FLAW wire ESAB 71 T or equivalent.
Intermediate Run 1.2 or 1.6 mm Capping Run 1.2 or 1.6 mm
Following acceptance of a welders qualification by the company representative, or on satisfactory 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 stamped on every weld he performs in systems where examination of the completed weld is a requirement. The welder identification mark will only be assigned for a particular task that will be defined at the time of issue. General Preparation for Welding Pipe may be cut either by mechanical means or by flame cutting, depending on the type of material to be cut. For carbon steel, flame (or arc) cutting and bevelling of the cut edge is only acceptable if the cut is reasonably smooth, true and all oxides are removed from the flame cut surfaces by grinding. After flame cutting the bevelled end, preparation shall be ground back to bright and sound metal. For stainless steel, plasma cutting and machining of the cut end is preferred. Grinding back to bright, sound metal is required. The pipe ends cannot be machined. Flame cutting is not allowed. All welding shall be undertaken in areas adequately protected from inclement weather conditions 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 cold hammering as a means for repair is prohibited.
General Preparation for 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. Seal welding 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 minimum gap of 1.6 mm shall be maintained between the end of the pipe and the bottom of the socket.
Socket Weld Valves Because of the possibility of seat distortion due to welding heat, the valve stems shall be in the open position prior to commencement of welding. This is applicable to all valve types and sizes.
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7.4
Inspection and Testing Inspection All 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 company representative. 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 additional examination necessary to ensure compliance with this specification. NDT and pressure test records shall be submitted to the manager for approval.
The level of examination required for each piping material specification has been nominated in Schedule 8. Inspection and testing for the quality of fabrication must be carried out prior to any painting or coating is applied. Non-destructive testing of welds shall be carried out after final heat treatment is completed. All radiography shall be conducted by competent radiographic examiners in accordance with a NATA approved procedure. The cost of weld repairs as a result of failures detected by radiography together with the cost of re-examination will be at the contractors account. The welder whose work does not pass radiographic examination shall have double the specified number of welds examined. The additional welds to be tested shall be chosen from those welds not previously examined. If additional welds tested comply then the costs of this additional testing will be borne by the Company. Should the additional welds tested not comply, all remaining welds having a specification subject to some form of radiography shall be examined and repaired at the contractors cost. The welder responsible for the failed welds shall cease to be recognised as being coded in that particular procedure. Schedule 8 - General Requirements for Testing Both Off Site and On Site. Meaning of Abbreviations: RT MPT HT LPT WTWP PT FWT Radiographic Testing Magnetic Particle Testing Hydrostatic Testing Liquid Penetrant Testing Water Testing at Working Pressure Pneumatic Testing Field Weld Testing
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Piping Material Specification 1.
Inspection and Testing Requirements Piping Material Carbon Steel Rubber Lined Off Site Fabrication 10% RT at Random 50% Visual Inspection 100% Spark Test 10% MPT at Random N/A N/A 5% MPT on Fillet Welds 20% Visual Inspection 10% RT at Random 10% MPT at Random 50% Visual Inspection 5% MPT on Fillet Welds 20% Visual Inspection 10% RT at Random 10% MPT at Random 50% Visual Inspection Registered Welders Mandatory Registered Welders Weld Maps and Recordings 10% MPT at Random 50% Visual Registered Welders On Site Fab / Installation 100% WTWP
2. 3. 4.
Carbon Steel Carbon Steel Carbon Steel (Service Waters) Carbon Steel (oils and Gases)
50% Visual Inspection 100% WTWP 30% Visual Inspection 100% HT 30% Visual Inspection 100% HT 5% RT at Random 10% MPT at Random 50% Visual Inspection 100% HT 50% Visual Inspection 100% PT 100% Visual Inspection FWT 10% LPT at Random 100% HT Registered Welders Mandatory 100% WTWP Registered Welders Weld Maps and Recordings 100% HT 10% MPT at Random 50% Visual 100% HT Registered Welders 100% HT
5. 6.
Carbon Steel Galvanised Stainless Steel
7.
Polyethylene PE100 (General Services) Polyethylene PE100 (High Pressure) where specified
8.
Carbon Steel
9. 10.
Not Used Polypropylene
Repair or Defects Repairs to welded joints, defective or damaged pipe fittings or any other pressure part shall not be carried out without written approval of the company representative and shall be shown as a hold point on the ITP. Repair procedures shall be approved by the company representative prior to commencement of work. If repairs or modifications are carried out after heat treatment has been completed, the areas affected by the repair or modification shall be heat treated again.
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8. 8.1
INSTALLATION, ERECTION AND CONSTRUCTION (SITE WORKS) General Requirements All piping shall be installed in accordance with the drawings. Flanges or unions shall be installed to allow installation, removal or maintenance of equipment or valves without dismantling pipe or steelwork forming part of an adjacent system. Modifications to pipe routing may be necessary at site to avoid interference. These modifications shall be carried out in a neat and workmanlike manner in accordance with AS 4041 and Section 8 of this Specification. All modifications to the designs represented on the issued for construction drawings shall be marked by the contractor on as-built drawings. Straight run pipe shall be lifted in and not be pulled through the pipe racks. A straight run of pipe shall contain the minimum number of welds. The use of off-cuts in straight piping runs shall be avoided. Piping butt welds shall be spaced a minimum of 50 mm apart or a distance of four times the thinnest wall thickness between the heat affected zones, whichever is greater. Cold springing or deflection of piping for the purpose of joint make up is not permitted unless specified on the drawings. Misalignment beyond acceptable tolerances in straight pipe runs shall not be permitted. Pipes passing through concrete walls or floors shall not be cast in. Pipe shall be passed through cast in sleeves having an internal diameter large enough to give 12 mm radial clearance to the passing flange, including its lagging, where applicable and shall contain a light infill if air passage is to be restricted. Where pipework passes through chequered plate floors or grid mesh, a 100 mm high collar having an internal diameter large enough to give minimum 25 mm clearance to the passing flange shall be welded to the chequered plate/mesh. Penetration of fire walls for passing pipes shall not be permitted. Erection of pipework using victaulic couplings shall be in accordance with the Suppliers recommendations. For site fabrication and installation of piping, a methodology statement shall be provided to the company representative for approval prior to work commencing.
8.2
Cleanliness and Protection Pipework and fittings stored on site shall be kept clear of the ground and regularly examined for corrosion or damage. The contractor shall ensure by regular examination that stored materials do not deteriorate and shall renew any corrosion protection as necessary. Non-metallic or lined piping shall have ends capped until installed. It shall be the responsibility of the contractor to ensure that the completed pipework is free from obstruction or loose foreign matter. Before pressure tests are carried out the contractor shall ensure that the inside of all pipes, valves, fittings and other associated equipment are clean and free from loose foreign matter. Where equipment which could be damaged by debris is included in a test system, temporary in-line strainers shall be installed by the Contractor to protect these items.
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The site shall be left clean and tidy at the completion of each day. Surplus materials shall be gathered and disposed of or stored as directed by the company representative. All work shall be carried out in a safe and orderly manner in accordance with accepted safe operating practices. 8.3 Installation of Valves Valves shall be installed as indicated on the piping drawings and hand wheels and levers shall be easily accessible for operation from grade or platform. Valves shall not be installed with their stems projecting into walkways. All valves located underground or in trenches shall be provided with valve boxes and extension stems. These items may not necessarily be shown on drawings but will form part of the minimum requirements. Relief valves shall be installed in an upright position and be accessible from a platform or grade. Relief valves discharging hazardous liquids or gases, shall be piped to a safe and environmentally acceptable location. Chain wheel operators shall be provided for valves with hand wheels more than 2050 mm above the operating floor level. Chains shall clear operating floors by 900 mm and shall not hang in access areas. The contractor shall be responsible for checking the position of all valve stems, hand wheels and levers for accessibility and freedom of operation to the satisfaction of the company representative, whether the location/orientation of the valves are detailed on piping drawings or not. 8.4 Piping for Rotating Equipment Piping connected to pumps and compressors shall be installed up to a break point between the nearest pipe support and the equipment. The remainder of the piping shall be site measured, fabricated and properly fitted between the equipment connection and this break point. It is essential that this is done accurately in order to avoid any external loadings on the equipment connections. Piping shall be disconnected from the equipment after installation and reinstalled to demonstrate that no stress has been transferred from piping to equipment. The following procedure shall be applied for the alignment of flanges to rotating equipment: Install, bolt down on shims and grout rotating equipment level on the foundation. Driver to equipment alignment to be set within manufacturers tolerances. Align pipework to equipment flanges to within the Suppliers tolerances and in accordance with this specification.
Recheck the coupling alignment during the bolting and tensioning of the pipes to the equipment flanges. The bolting up and tensioning of the flanges shall not affect the coupling alignment between the driver and the driven equipment.
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8.5
Flanged Joints and Bolting Bolts and stud bolts of diameter 20 mm and larger shall be tightened by torque wrenches or other tightening methods which result in uniform tightening of the flanges. Bolt torques for valves and lined piping shall be in accordance with the Suppliers recommendations. Flanged connections shall be tightened sequentially, diagonally opposite, in a clockwise or anticlockwise order so that an even gasket seating will result. Flanged spools mating with equipment flanges shall be site fitted for correct alignments to ensure that no stress or load is placed on the equipment. Before flanged pipe spools are finally connected to pressure vessels, heat exchangers or flanged equipment, an inspection shall be carried out by loosening up to 10% of the flanged or union connections to the equipment to ascertain that no stress is placed on equipment due to misalignment of the pipe. The surface of flange gasket faces shall be free from rust, weld spatter, scars, paint, dents, arc strikes, corrosion pitting and other imperfections. All flange connections shall be made using fully threaded stud bolts, bolts and nuts. A minimum of one and a maximum of three completed threads shall protrude from the nut after completion of tightening. Insulating gaskets shall be installed when shown on the piping drawings. Care shall be taken not to damage the bolt sleeve and gaskets when installing insulation gaskets. Bolts, studs and nuts shall be protected by an anti seize compound. All studs shall be screwed home a minimum of one diameter. Teflon tape or other suitable pipe sealing compound (eg. Loctite 567) shall be used as a sealant on all threaded connections.
8.6
Pipe Supports Piping shall be supported, guided and anchored, as per the piping design and support detail drawings. Temporary supports are permitted to facilitate piping installation provided they shall be completely removed upon completion. Attaching temporary supports to stainless steel, alloy steel, carbon steel piping or lined pipes by welding is not permitted. Pipe shoes and sliding pipe support attachments shall be centred over the concrete or steel support beams before any field welding or bolting is carried out. Pipe supports shall be strong enough to support the weight of the pipe and its contents and shall be so placed as to prevent sagging in lines, to oppose any forces tending to misalign or separate the pipes, to allow removal of valves and/or equipment and maintain the line in its installed position and to offer rigidity to valves for proper operation. Schedule 9 details the recommended spacing for site run service pipes where no design drawing is available. This table must be read in conjunction with the standard pipe support drawings. Small bore pipe may have intermediate support from large bore pipe over 8 (200 NB) where no structure is available for support.
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Schedule 9 - Service Pipe : Pipe Support Centres.

Support Centres in Metres Water Services 2.00 2.40 2.70 3.00 3.40 3.90 4.30 5.20 6.00 7.00 8.00 8.40 Air and Gas Services 3.00 3.30 3.70 4.00 4.50 5.10 5.20 6.50 7.50 9.00 10.00 10.60
Pipe Size NB (20) 1 (25) 1 (32) 1 (40) 2 (50) 3 (80) 4 (100) 6 (150) 8 (200) 10 (250) 12 (300) 14 (350)
No pipe shall be supported by welding the pipe to a bracket, support, or any part of the structure. Unless otherwise noted on drawings, pipework will be retained by U Bolts (with their fixing holes drilled) or hanging clamps/brackets of an approved design. All PVC, Polyethylene (PE) and Polypropylene (P:P) pipe shall be continuously supported in cable trays (Nema 20B) manufactured from galvanised or stainless steel. The cable ladder shall be supported at 4.5 m to 6.0 m centres dependant of the line sizes being carried and to the satisfaction of the company representative, if not detailed on design drawings. Where polyethylene lines are greater than 10 IPS (280 OD) in size it is not mandatory for it to be continuously supported in cable ladder and as a guide based on PE 4710 (DR 17) pipe, schedule 9.1 details support centres for polyethylene (PE) pipe carrying water as recommended by the manufacture. Schedule 9.1 - Polyethylene Service Pipe : Pipe Support Centres.
Pipe Size NB 6 IPS 8 IPS 10 IPS 12 IPS 14 IPS 16 IPS 18 IPS 20 IPS PE 4710 Rating 2.20 2.75 2.95 3.45 3.75 4.05 4.35 4.95
8.7
Insulated Piping This section of the specification covers the materials and application of thermal insulation of interior and exterior piping. This specification covers operating temperatures between 10 degrees Celsius
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and 180 degrees Celsius. All pipelines requiring insulation are so noted on the P&IDs and Design Drawings. These lines will be designated as TI for thermal conservation and PP for personnel protection. Refer to section 5.5 in this specification for guidance on how the lines are nominated. The thickness of insulation called up in the specification relates to the nominal thickness of the insulating medium and does not include the finish covering or weather proofing materials. Thermal conservation (TI), requires an insulation thickness of 2 (50 mm). Personnel Protection (PP). This pipe shall be insulated up to 2.5 m above any floor, platform or walkway, and within 2 m horizontally from any handrails or ladders. All piping operating above 60 degrees Celsius shall be insulated for personnel protection. Insulation thickness shall be a minimum of 25 mm. Unions, pipe flanges, valves, steam traps, pipeline guides, pipeline supports and expansion joints shall not be insulated. Insulation shall not be installed until all piping has been inspected and tested for leakage and made tight. For pre-insulated piping or piping with shop applied insulation every precaution shall be taken to ensure that insulated parts remain weatherproofed at all times during storage, handling and erection to prevent moisture from being absorbed into the insulation materials. Where materials are identified by trade name, other materials of equal quality may be used with the approval of the company representative. Alternatives must be applied in the appropriate thickness to ensure insulating properties which are equal to or better than the nominated product. All insulation shall be installed using only first grade quality materials and workmanship. All surfaces to be insulated shall be cleaned of all dirt, oil, grease and foreign matter. Where nominated, all pipework should be blasted and primed prior to insulation being applied. Insulation materials used inside buildings shall be manufactured from rigid, high density moulded fibreglass, bonded with an inorganic filler material. Insulation shall be supplied with a factory applied fireretardant jacket incorporating longitudinal overlaps and end-jointing strips. This jacketing shall also be suitable for use as a vapour barrier. The thermal conductivity values of insulating material shall be:
Temperature 10 degrees Celsius 80 degrees Celsius "K" Valve 0.23 0.25
Insulation material for use outside buildings shall be rigid, high density moulded fibreglass, bonded with an organic filler material. The insulation shall be supplied with a factory applied fire retardant jacket incorporating longitudinal overlaps and end-joint strips supplied. The supplied jacketing shall also be suitable for use as a vapour barrier. Unless otherwise nominated on the drawings all cladding for insulated pipework shall be manufactured from 0.50 mm thick 304 stainless steel sheet. The cladding shall be fitted to the insulated pipe with lapped joins and swaged edges to shed water. All laps in the cladding shall be riveted at 150 mm centres for circumferential laps, stainless steel rivets to be used.
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8.8
Stainless Steel Piping Special precautions shall be taken during the fabrication and erection of stainless steel piping when in close vicinity of carbons steel piping. Direct contact between stainless steel and carbon steel pipe is not permitted. Stainless steel or PTFE spacer strips of adequate size shall be installed in areas where stainless steel piping rests on carbon steel supports.
8.9
Plastic Piping The installation and testing of plastic piping systems shall be in accordance with: AS 2033 - Installation of Polyethylene Pipe Systems. AS 2032 - Installation of UPVC Pipe Systems.
Polyethylene pipe connections shall be made using compression fittings, fusion weld fittings (site), butt weld fittings or using mechanical joint fittings in accordance with this specification. Flange rings shall be installed when plastic pipe flanges are connected to valves. Spacers shall be used when wafer type butterfly valves are used in plastic pipelines to ensure free movement of the disc inside the pipe. Polyethylene piping shall be laid so that it is capable of operating between the maximum and minimum service temperatures. There shall be sufficient excess length between anchors to allow for contraction, and sufficient space allocated for expansion. Adequate allowances shall ensure that no excessive residual stresses remain in the piping prior or post start-up of the pipeline. U-bolt guides with two lock nuts loosely clamped may be used to allow free movement of the pipe in operation due to expansion and contraction. Socket connections in UPVC pipe shall be made using solvent cement as recommended by the supplier. Threaded joints shall use Teflon tape or thread seal compound on male threads only. In slurry services, pipes shall be flanged or have a victaulic connection at least every 18 m and in solution service pipes, shall be flanged or victaulic at lease every 36 m unless specified otherwise. Spools may be prefabricated in convenient lengths for installation on site. 8.10 Rubber Lining Rubber lining of pipes shall conform to British Code of Practice CP 3003 Part 1 incorporating all amendments. Unless otherwise specified or indicated on the drawings the lining shall be 6 mm thick and comprise natural rubber with a shore hardness (scale A) of 45 - 55. Lining other than natural rubber shall have relevant data submitted for approval by the company representative. The thickness of rubber facing on flanges to be as specified on the detail drawings. The inside surface of pipes are to be clean, smooth and free from weld splatter prior to lining. The contractor shall ensure that the dimensions of the piping and fittings to be lined conform to the requirements of CP3003. Should there be any discrepancy or conflict between the Drawings and the requirements of CP 3003, the contractor shall refer the matter to the company representative for resolution.
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8.11
Polyurethane Lining Where required, piping shall be lined with VARASALON E90A (or equivalent) grade polyurethane. This grade is suitable for transporting slurries containing particles up to 90 microns. Manufacturers recommendation shall be sought for the correct grade of polyurethane to be used for slurries having particles larger than 90 microns. Continuous straight pipe lengths up to 12 m can be lined with polyurethane in diameters 50 mm and above. Each end of the pipe shall be flanged, bends and elbows must have "Vanstone" flanges at both ends. Gaskets are not required. The lining shall be continuous and cover the face of each flange. Polyurethane lining shall only be used when the temperature of the contained fluid will be between 15 and 75 degrees Celsius. The manufacturers advice shall be obtained when caustic or acid solution exceeding 20% concentration is to be conveyed in the lined pipes. Polyurethane lining shall be applied to the nominated thickness: 3 50 - 80 mm NB 4 8 100 - 200 mm NB 10 250 + NB 3 mm thick 6 mm thick 8 mm thick
The inside surface of the pipe shall be made clean, smooth and free of weld splatter prior to application of the polyurethane. Any cutting or welding after lining shall be made good by grinding away all damaged lining and applying trowelling consistency polyurethane of the same specification as the original lining. 8.12 Galvanised Piping Pipe and fittings 2 (DN 50) and below shall be supplied galvanised with screwed ends in accordance with this specification. Pipe 3 (DN 80) and larger shall be shop fabricated and hot dipped galvanised in accordance with ASTM A123/A123M. If any modifications are required to a galvanised spool 3 (DN 80) and larger during installation, the spool shall be modified and hot dipped galvanised again. A procedure for minor repairs to galvanised pipe and fittings using cold galvanising shall be submitted to the company representative for approval. Any repairs using cold galvanising shall be a hold point. 8.13 Mining Hose The hoses shall be stored in a cool dry location away from direct sunlight and high temperatures. Mining (Material handling) hoses shall be handled carefully. Nylon slings shall be used and properly placed while handling mining hoses in order to support the hose properly. The hose shall not be kinked while handling or erecting. A minimum bend of 10 D shall be used for any mining hose installation. The hose shall not be dragged over or supported on sharp or abrasive surfaces. Integral or beaded flange ends are the preferred method of connecting hose to fixed pipe. Where hose lengths are required to be site measured, muff couplings can be used for hoses up to and including 12 (300 DN). 8.14 Under Ground Piping Trenching Trenches shall be excavated to the required alignment, width and depth shown on the drawings. Additional width may be required dependant on trench depth to allow safe working clearance for work within the trench. The minimum earth cover over the top of pipes shall be 600 mm unless otherwise stated in the specification or specified on the design drawings. The bottom of the trench shall be cut with the design falls and grade

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into firm soil to afford bearing for the full length of the pipe. Sand fill shall be used to provide an even bedding. Over excavation shall be corrected with sand fill, thoroughly compacted to achieve the in-situ soil density. Trenches that are exposed to inclement weather may require sumps to be excavated and the trench floor graded to drain collected water into the sump. Trenches must be free of water and well drained prior to laying pipe and backfilling commencing. Coating and Wrapping All exterior surfaces of buried steel piping, fittings and valves shall be primed and wrapped with a suitable corrosion protection tape system (e.g. Denso). Flanged joints on polyethylene lines shall also be wrapped. The external surfaces of steel pipe and fittings to be primed and wrapped, shall be clean, dry and free of any oil and grease prior to the commencement of wrapping. Wrapping material shall be polyvinyl chloride pressure sensitive tape or approved equivalent 0.5 mm thick. Widths shall be 50 mm for pipe diameter up to 50 mm; 100 mm for pipe diameter 80 mm to 200 mm and 150 mm for pipe diameter 250 mm and larger. Tape shall be spirally wrapped onto the steel pipe and fittings starting on the mill coating 80 mm from the edge using 12 mm overlap and extending 80 mm over the adjacent mill coating. Inspection and Installation Pipe and fittings shall be inspected for defects prior to lowering into the pipe trench. Coated and wrapped steel pipes shall be laid directly on the trench floor by lowering the pipe carefully into the trench using canvas or leather slings to ensure the protective coating is not damaged. Any damage to the coating during installation shall be repaired immediately. When repairing damaged coatings, the wrapping in the defective area shall first be removed and the pipe re-wrapped in accordance with the coating and wrapping procedure. Where lining continuity testing is required, the recommended voltage for the holiday test detector shall be approximately 400 volts for each 100 microns thickness of wrapping. Cathodic protection, if required, shall be provided in accordance with EN 12954:2001. Bedding and Laying The pipe shall be laid directly on screened, sand or specified bedding material on the trench floor. Holes shall be hand dug for flanges and couplings to provide continuous contact of the pipe with the trench floor. Pipe shall be clean inside when placed in the trench. Open ends of all pipes must be capped to prevent foreign matter from entering the pipe. Trenches must be free of excess water during installation of the pipe. Pipe, fittings and wrappings shall be inspected for defects prior to lowering into the trench. Prior to backfilling a survey of all lines for alignment and level shall be undertaken providing co-ordinates for change in direction and depth of top of buried pipe. Backfilling After all testing and survey is complete, all piping shall be backfilled and compacted for the full length of the trench. In the vicinity of roads and buildings, sand backfill shall be placed in layers and compacted to a minimum density of 95% dry density (modified). In open areas backfill shall be compacted to 90% standard proctor dry density. Backfill shall be selected material and free of coarse gravel, stones, debris etc. The placing and compacting of backfill shall be uniform and in layers no greater than 200 mm thick to ensure the proper alignment of the piping and to avoid damage. Backfill shall be
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thoroughly compacted investigation. Post Erection
using
appropriate
methods
determined
by
geotechnical
All buried lines are to be thoroughly flushed out prior to filling the pipelines as part of the hydro-test procedure. 9. 9.1 COMMISSIONING AND TESTING Pressure Testing Test Requirements Pressure testing shall be carried out in accordance with the requirements of AS 4041 and this specification. Pressure piping comprises the piping design and materials to convey or contain fluids at either a positive or negative internal pressure and shall be tested as follows: Shop hydrostatic testing of piping spools will not be routinely required, unless specified otherwise on the design drawings. Shop hydrostatic testing is required for piping spools that are to be hot dip galvanised. The spools shall be hydrostatically tested prior to galvanising.
Pressure piping shall be either hydrostatically on pneumatically tested in accordance with this specification. The test pressure to be used shall be as nominated in this specification. Open ended vent, drain and similar piping systems operating at atmospheric pressure are not considered as pressure piping and do not require pressure testing but shall be leak tested by filling the lines with water when directed by the contractors representatives. The "Test Section" of site QA documentation shall contain isometrics of relevant sections of pipework related to the section of piping system that is being tested and the following information: Limit of test illustrated on the P&IDs. Location and thickness of test spades. Test medium. Test pressure. Location of vents and drains. Requirements for isolation or removal of inline equipment and instruments to complete the test.
The testing procedure shall be submitted to the company representative for approval prior to any work commencing (refer section on test records). Sections of pressure piping which must be removed to permit installation of test blinds shall be tested separately. Flanged connections at points where blinds are used during pressure tests do not require separate testing but shall be inspected thoroughly to assure tightness.
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Test Medium For hydrostatic testing of carbon steel piping systems, the test medium shall be potable water at ambient temperature. If potable water is not available permission will need to be sort for the use of another type of water available (eg. Bore water). Approval of an alternative fluid may require the submission of a water analysis detailing the chloride content and pH value of the water.
Pneumatic Testing Pneumatic testing of a piping system is not permissible unless prior approval is obtained from the company representative. Pneumatic testing shall be performed in accordance with AS 4041 and the additional requirements of this specification: Test medium : Dry nitrogen or clean, dry, oil free air. Area of test to be roped off and access into the area be limited. The minimum metal temperature during a pneumatic test of piping shall not be less than the maximum temperature allowed by the engineering design. Piping system to be tested shall be protected by a safety valve. Set pressure of the safety valve shall be : Test pressure plus the lesser of 70 kPa or 7% of the test pressure. Weak soapy water shall be used for testing for leaks.
Test Duration Unless otherwise specified, the test pressure shall be held for a minimum period of one (1) hour to enable thorough inspection of the piping system and components for leaks.
Test Equipment Equipment to be used during testing shall have suitable capacity for the range of test pressures required. All pressure gauges and chart recorders shall have been calibrated within 60 days prior to testing and shall have current calibration certificates. The gauges shall be of a minimum face size of 100 mm in diameter and ranged to approximately twice the test pressure. A minimum of two calibrated gauges shall be provided for the testing period.
Procedure For Testing Testing shall be carried out in the presence of and to the satisfaction of the company representative. The contractor shall open vents or other connections to ensure displacement of air from the pipework, before applying the fluid test pressure. Non-return or check valves shall have the test pressure applied simultaneously on both sides of the valves. On completion of the test the contractor shall ensure the release of the pressure on the downstream side of the valves. Any leaks shall be made good to the satisfaction of the superintendent. The pressure test shall be reapplied if any repairs have been carried out. The method of carrying out any repairs or adjustments shall be agreed with the company representative. If all pressure has been released to carry out a repair then the full test procedure shall be repeated. If however, an adjustment only has been made, then the test pressure need only be held for a further 15 minutes. After hydrostatic testing of the system is complete and approved by company representative, all lines and equipment shall be completely drained of the test fluid. The timing and manner of draining the test fluid shall be agreed with the companies
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representative. Care shall be taken when draining the test fluid to avoid damage to the pipeline and other items of equipment. Piping system vents shall be opened while draining to avoid developing a vacuum in the pipe. Special attention shall be given to points where water may be trapped, such as in valve bodies or low points. Test Records Records for tests which require that pressure be held for a specified period of time shall include any corrections of test pressure due to temperature variations between the start and finish of the test. Records of all test carried out and approved by the company representative shall be retained in the job quality documentation. Minimum requirements for documenting the tests results and details are noted under test requirements in this section. 9.2 Cleaning and Reinstatement Cleaning Completed systems shall be internally cleaned to remove all foreign matter by water flushing or blowing with air. Flushing shall be done with potable water if the pipeline is to be hydro tested. Where special conditions exist such as cleaning of compressor suction and lube oil piping, a separate cleaning procedure shall be prepared and submitted to the superintendent for approval. Piping and equipment shall be dried prior to filling with process fluid for commissioning if required. Reinstatement After successful completion of pressure testing, the system shall be returned to a state of commissioning readiness.
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Ts12 Technical Specification - Piping

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TECHNICAL SPECIFICATION

Piping SANTA ELENA - MEXICO

Approved By SD PDS RDS RDS PP RDS RDS RDS

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Materials for High Temperature

TECHNICAL SPECIFICATION PIPING

ASTM D2737 ASTM D3035

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

SS Std Wt TIG UNS WN 4.

TECHNICAL SPECIFICATION PIPING

Pipe Size (inches)

Tap Drill (inches)

2-7/32 2-5/8 3-1/4 3-3/4 4-1/4 4-3/4 5-9/32 6-11/32

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Line Prefix EW EL FW FL WF FR Fr Fr Fr Fr GW GRW HPA

TECHNICAL SPECIFICATION PIPING

Line Specification 05,07 04 04, 04,07

Service Pressure kPa 600 Atmos 400

Hazardous ID Requirement No Yes No No

Colour Coding AS 2700 G21 B25 N61 Jade Aqua Black

Piping Specification, Hazardous Identification and Piping Color Schedule

TECHNICAL SPECIFICATION PIPING

Carbon Steel NPS (in)

PVC DN (mm) 15 20 25 32 40 50 80 100 125 150 200 250 300 -

NPS: DN: I.P.S:

TECHNICAL SPECIFICATION PIPING

Valve Type - Ball Valve

Valve Size - 40 Nominal Bore

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Piping Material Specification 1

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Piping Material Specification 2

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Piping Material Specification 3

Hose Down Water - Process Water (HDPW) 1000 kPa

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Piping Material Specification 4

Valves: Series 2(DN 15 50) Series 2 (DN 65) and above

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Piping Material Specification 5

TECHNICAL SPECIFICATION PIPING

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

TECHNICAL SPECIFICATION PIPING

Piping Material Specification 6

TECHNICAL SPECIFICATION PIPING

TECHNICAL SPECIFICATION PIPING

Piping Material Specification 7

High Density Polyethylene PE 4710

AS 4129, ASTM D3139? AS 4129, ASTM D3139?

TECHNICAL SPECIFICATION PIPING