Aac Spec 412010

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING
412010 ISSUE 2 COPYRIGHT

PAGE
CONTENTS
1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 5.3 5.4 6 6.1 6.2 7 7.1 7.2
SCOPE TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER PIPE OUTSIDE DIAMETER INSULATION SECTION LENGTHS TOTAL LENGTH OF PIPING BEND OR PIPE FITTING DETAILS PIPE MATERIAL PIPE JOINT DETAILS (FLANGED OR SHOULDERED) REQUIRED LIFE OF CORROSION PROTECTION THE PREVAILING AMBIENT CONDITIONS AFFECTING CORROSION PACKAGING REQUIREMENTS. PIPES TO BE PRE-INSULATED ON SURFACE OR INSULATION TO BE INSTALLED IN-SITU UNDERGROUND. DEFINITIONS REQUIREMENTS GENERAL MATERIALS INSULATION SYSTEM CONSTRUCTION DESIGN QUALITY ASSURANCE REQUIREMENTS QUALITY MANAGEMENT SYSTEM QUALITY PLAN INSPECTION SAMPLING INSPECTION AND TEST TYPE TESTS PRODUCTION TESTS MARKING AND PACKING MARKING PACKING
2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 4 5 5 7 7 7 7 7 8 8 8 9 9 10 11 11
APPENDIX A : RELATED DOCUMENTS APPENDIX B : RECORD OF AMENDMENTS
AAC_SPEC_41201002.DOC
APPROVED
11 July 1994
Page 1 of 11
Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or the information contained therein, irrespective of the cause and quantum thereof.
SCOPE
This specification details the requirements for the thermal insulation of chilled water pipes installed underground and covers pre-insulation of pipes on surface and in-situ applications underground.
2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3
TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER PIPE OUTSIDE DIAMETER INSULATION SECTION LENGTHS TOTAL LENGTH OF PIPING BEND OR PIPE FITTING DETAILS PIPE MATERIAL PIPE JOINT DETAILS (FLANGED OR SHOULDERED) REQUIRED LIFE OF CORROSION PROTECTION THE PREVAILING AMBIENT CONDITIONS AFFECTING CORROSION PACKAGING REQUIREMENTS. PIPES
TO BE PRE-INSULATED ON SURFACE OR INSULATION TO BE INSTALLED IN-SITU UNDERGROUND.
DEFINITIONS
ACCEPTABLE/APPROVED CSIR MINING TEK : : Acceptable to and approved by the Engineer Council fir Scientific and Industrial Research Mining Tek The Consulting Engineer, Consulting Mechanical and Electrical Engineer of AAC or their appointed representative Combination of one or more of sleeve, vapour barrier and insulant so providing required properties Material providing thermal insulation through low heat transfer National Building Standards Naval Engineering Standard (Royal Navy)
ENGINEER
INSULATION SYSTEM
INSULANT
NBS NES
: :
APPROVED
11 July 1994
Page 2 of 11
PIPE SLEEVE UPVC VAPOUR BARRIER
: : : :
Water reticulation pipe Outer covering which provides protection to the insulant Unplasticised poly-vinyl chloride Layer of continuous impermeable material sealing the insulant
The following terms are defined in the General Conditions of Contract: AAC, Company, Contractor.
4 4.1
4.1.1
REQUIREMENTS GENERAL
Insulants produced by the chemical reaction of two or more constituents, which during the chemical action produce a water vapour: shall not be injected or cast into a closed void unless:
4.1.1.1 Provision is made: to vent this moisture from the insulant to ensure that the coefficient of conductivity specified by the manufacturer is obtained. This conductivity must be stabilised after the insulation has been used in the conditions shown in table 5 for a period of 200 hours. 4.1.2 Insulants produced by the chemical reaction of two or more constituents, one of which is an acid, shall not be used as slab stock in voids, or be injected into voids which have metallic walls unless the walls are suitably protected against corrosion.
4.2
4.2.1
MATERIALS
Sleeve: the sleeve shall comply with the requirements specified in Table 1. TABLE 1: SLEEVE REQUIREMENTS
1 MATERIAL UPVC (See note below) 1. 2. 3. 2 REQUIREMENTS Maximum thickness 3,2mm Impact resistance minimum value 50 kJ/m Comply with AECI Specification No. 130/S/03 or approved equivalent UPVC sleeves must be colour coded blue DIN 53448 3 TEST METHOD
4.
APPROVED
11 July 1994
Page 3 of 11
Steel Phoenolic Resin Glass reinforced
Minimum thickness 0,3mm See AAC Specification 173/1
Note: Where UPVC sleeved piping is routed closer than 2,0m from fuelling bays, oil stores, conveyor belts, oil filled transformers and switchgear, timber supports, etc, external steel cladding shall be applied. See AAC Drawing No Y1903. 4.2.2 Vapour barrier: the vapour barrier shall comply with the requirements specified in Table 2. Where pipe insulation is purchased without a mechanical protective sleeve, the vapour barrier material shall comply with the AAC Specification No 412/9. TABLE 2: VAPOUR BARRIER REQUIREMENTS
1 PROPERTY Water Vapour 2 REQUIREMENTS 0,2g maximum per m/24h at 38C 2% and 90% R.H. 5% R.H. 3 TEST METHOD ASTM E96
4.2.3
Insulant: the insulant shall comply with the requirements specified in Table 3. TABLE 3: INSULANT REQUIREMENTS
1 PROPERTY Combustibility Pass 2 REQUIREMENTS 3 TEST METHOD SABS 0177 Part V (Modified) CSIR Test Method Toxicity Thermal Conductivity Smoke Production Optical Density Value Min Compressive (Parallel to Rise) Density Specific Strength Maximum Index of 2 0,05 W/mC Max Maximum index of 10,0 175 kPa Max 200kg/m SABS Test Method TI (NES) ASTM C177 NBS Smoke Method Density Test
4.3
INSULATION SYSTEM
The insulation system shall comply with the requirements specified in Table 4.
APPROVED
11 July 1994
Page 4 of 11
TABLE 4: SYSTEM REQUIREMENTS

1 PROPERTY Fire Resistance Thickness of insulant Thermal Conductivity Heat gain Distortion (Pre-insulated pipes) Pass Clause 4.4.2 To be specified by Contractor 0.05 W/m C max Table 6 10mm 2 REQUIREMENT 3 TEST METHOD CLAUSE CSIR Mining Tek/CSIR Fire Lab. Tunnel tests CSIR Mining Tek Dynamic Test (see Clauses 6.2.8 and 4.4.2) ASTM C177 CSIR Mining Tek Dynamic Test Clauses 6.2.5
Note: The overall length of insulation system on pre-insulated pipes shall allow adequate access to flange bolt holes etc.
4.4
4.4.1 4.4.2
CONSTRUCTION
Insulant: shall be homogenous, free of voids and shall occupy all cavities within the protective sleeve. Thickness of insulant: shall be such that the heat gain values detailed in Table 6 shall not be exceeded after ageing and after use for 200 hours in conditions as set out in Table 5. Water vapour protection: of the insulant shall be such that it is encapsulated in a material which complies with the requirements for a water vapour barrier as detailed in Table 2. Where this material is joined, the joint shall exhibit the same characteristics as the parent material. Products of organic nature: polyurethane or polystyrene based materials shall not be used. The density of the insulant: shall not be greater than 200 kg/m3.
4.4.3
4.4.4
4.4.5
The complete product: comprising insulant, water vapour barrier and sleeve shall not show any deformation greater than 5 mm nor any permanent visible deterioration when tested in accordance with the requirements of Clause 6.2.7. Glass reinforced organic material: if used as a protective sleeve shall comply with the requirements of AAC Specification 173/1.
4.4.6
4.5
DESIGN
The Contractor shall provide for approval, dimensioned drawings and design calculations at time of tender response accompanied by an SABS certificate stating that an insulation system complying with the design has been tested by SABS and complies with the requirements of Clause 4.2 and 4.3. The results of the heat gain tests and fire performance tests conducted by CSIR Mining Tek and CSIR Fire Lab. shall be included.
APPROVED
11 July 1994
Page 5 of 11
The Contractor shall also provide for approval the methods and materials used for fixing insitu type insulation to the pipes. 4.5.1 Calculations: the parameters detailed in Table 5 shall be used for design purposes. TABLE 5: CALCULATIONS PARAMETERS
1 PARAMETER Water velocity Water Temperature Pipe diameter range Pipe wall thickness Pipe thermal conductivity VALUES 1m/s 5C 100 - 300mm 6mm 45W/m C (Mild steel) Air temperature Air velocity 32C 5m/s 2
Note: If pipes of different thermal conductivity are used this shall be specified by the Company. 4.5.2 Design performance requirements: maximum heat gain per linear metre of insulated pipe shall not exceed the value given in Table 6. Note: Value given is for the combined insulating value of pipe wall, vapour barrier and sleeve and is based on a dry clean sleeve outer surface. TABLE: 6 HEAT GAIN
1 PIPE: NOMINAL SIZE (mm) 100 150 200 250 300 2 HEAT GAIN (W/LINEAR m) 14 19 24 29 34 3 TEST METHOD See Clause 6.1.2
4.5.3
Designed maximum outside diameter: of insulation shall comply with the requirements of Table 7.
APPROVED
11 July 1994
Page 6 of 11
TABLE 7 MAXIMUM INSULATION SYSTEM OUTSIDE DIAMETERS

1 NOMINAL PIPE SIZE (mm) 100 150 200 250 300 2 INSULATIONS, SYSTEM OUTSIDE DIAMETER (mm) 225 290 350 420 470
5 5.1
QUALITY ASSURANCE REQUIREMENTS QUALITY MANAGEMENT SYSTEM

The requirements of SABS ISO 9001 shall apply. All volitional requirements in SABS ISO 9001 shall be mandatory for material supplied against this specification.
5.2
QUALITY PLAN
The Contractor shall compile and submit a quality plan which shall be approved prior to commencement of manufacture. The quality plan shall list all major works, specifications, tests, methods of test and equipment to be used and acceptance/rejection criteria.
5.3
INSPECTION
The Contractor shall provide SABS certification to the effect that items supplied to the Company comply with the requirements of this specification. The Company's representative shall have access at all reasonable times to those parts of the manufacturing facilities engaged in the manufacture of items to this specification. He is authorised to witness any stage of manufacture, tests and inspection documentation. The representative is authorised to reject any items not manufactured to the requirements of this specification. All quality costs including SABS certification shall be for the account of the Contractor.
5.4
5.4.1 5.4.2
SAMPLING
Sampling for type testing: shall be as determined by the AAC Consulting Environmental Engineer. Sampling for production testing: shall be in accordance with the requirements detailed in the approved Quality Plan.
APPROVED
11 July 1994
Page 7 of 11
6 6.1
6.1.1
INSPECTION AND TEST TYPE TESTS

CSIR Mining Tek tunnel testing Full scale pipe insulation tests shall be performed on two 200 mm diameter insulated pipes complete with vapour barriers and external protective sheaths. The pipes shall be installed in parallel.
6.1.2
CSIR Mining Tek heat gain test An insulated 6m length of 150 mm nominal bore pipe shall be submitted to CSIR Mining Tek for the determination of the thermal conductivity of the insulation system at conditions as set out in Table 5.
6.2
PRODUCTION TESTS
Production tests shall be performed on samples as detailed in the Quality Plan and at the frequency specified in Table 8. TABLE 8 SAMPLING PLANS FOR TEST CLAUSE, 6.2
1 LOT SIZE 3 - 25 26 - 50 51 - 150 2 SAMPLE SIZE 3 13 20 3 DEFECTIVE ACCEPTABLE 0 0 0
6.2.1
Combustibility Combustibility shall be tested in accordance with the requirements of SABS 0177 Part V. (Modified) CSIR method.
6.2.2
Toxicity Toxicity shall be tested in accordance with the requirements of SABS Method T1 (NES 713).
6.2.3
Smoke density Smoke density production shall be tested according to the NBS Smoke Density Test method.
6.2.4
Conductivity The conductivity of a sample of the insulant shall be tested according to ASTM C177.
6.2.5
Water vapour transmission
APPROVED
11 July 1994
Page 8 of 11
The water vapour transmission values of the water vapour barrier or outside sleeve shall be tested according to ASTM E96. 6.2.6 Density of insulant Remove a cube from an insulated pipe and determine its mass. Calculate the volume of the cube and determine the density of the insulant by dividing the mass by the volume. Express 3 the result in kg/m . The result shall comply with the requirements of Table 3. 6.2.7 Distortion o Apply a force of 5kN, via a 50 x 50 steel angle positioned at 90 to the pipe axis, onto the outer surface of the insulated pipe (with the point of the 'V' of the angle contacting with the insulation). Remove the force and measure the depth of indentation. The results shall comply with the requirements of Clause 4.4.5 6.2.8 Thickness of insulant Measure thickness of insulant prior to encapsulation in the vapour barrier and outside protective sleeve, for in-situ type insulation. For pre-insulated pipes, measure the circumference of the pipe and the outside circumference of the protective sleeve of the insulated pipe. Calculate the thickness of insulation and protective sleeve and then deduct thickness of protective sleeve. The result shall comply with requirements to satisfy the heat gain specifications as set out in Table 6. 6.2.9 SABS 0177 Part V (Modified) CSIR combustibility The empty sample cradle shall be introduced into the furnace and the temperatures recorded for 5 minutes. When the furnace has reached equilibrium temperature a 40mm x 40mm x 40mm sample of the test material shall be introduced into the furnace and the temperatures shall be recorded for 5 minutes. Any material, of which the flame temperature rise exceeds that of the empty cradle for the initial 2 minutes of the test or which exhibits a quenching effect of less than that of the empty cradle for the initial 2 minute period of the test shall be deemed to have failed. The results shall comply with the requirements detailed in Table 6.
7 7.1
MARKING AND PACKING MARKING

The outer surface of the insulation system shall be marked as follows.
7.1.1 7.1.2
Logo or name of Contractor Date of manufacture

APPROVED 11 July 1994 Page 9 of 11
7.2
PACKING
Packing shall provide protection during transit and handling of insulation system components.
APPROVED
11 July 1994
Page 10 of 11
APPENDIX A : RELATED DOCUMENTS The latest issues of the following documents shall be deemed to form part of this specification. ASTM C177 : Test method for steady-state heat flux measurements and thermal transmission properties by means of the guarded-hot-plate apparatus Recommended practice for heat ageing of plastics without load Test for water vapour transmission of materials Quality management systems Fire testing of materials, components and elements used in buildings Fire testing of materials, components and elements (Modified) CSIR used in buildings Determination of the toxicity index of the products of combustion from small specimens of materials Specification for PVC formulation Testing of plastics; tensile impact test Cladding Vapour barrier for use with blanket type insulation for chilled water reticulation piping
ASTM D304 ASTM E96 SABS ISO 9001 SABS 0177 SABS 0177 Part V
: : : : :
SABS Method T1
AECI 130/5/03 DIN 53448 AAC Drawing Y1903 AAC 412/9
: : : :
APPENDIX B : RECORD OF AMENDMENTS Issue 2 : Table 8 added to Clause 6.2 Refs to COMRO changed to C.S.I.R. Mining Tek. (P.N. Eksteen 1994-04-11)
APPROVED
11 July 1994
Page 11 of 11

Aac Spec 412010

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AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

APPENDIX A : RELATED DOCUMENTS APPENDIX B : RECORD OF AMENDMENTS

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

PIPE SLEEVE UPVC VAPOUR BARRIER

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

Steel Phoenolic Resin Glass reinforced

Minimum thickness 0,3mm See AAC Specification 173/1

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

TABLE 4: SYSTEM REQUIREMENTS

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

TABLE 7 MAXIMUM INSULATION SYSTEM OUTSIDE DIAMETERS

QUALITY ASSURANCE REQUIREMENTS QUALITY MANAGEMENT SYSTEM

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

INSPECTION AND TEST TYPE TESTS

Water vapour transmission

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

MARKING AND PACKING MARKING

Logo or name of Contractor Date of manufacture

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

AAC SPECIFICATION THERMAL INSULATION FOR CHILLED WATER PIPING

412010 ISSUE 2 COPYRIGHT

AECI 130/5/03 DIN 53448 AAC Drawing Y1903 AAC 412/9

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