AAC_SPEC_412010

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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 orthe information contained therein, irrespective of the cause and quantum thereof.

AAC SPECIFICATION 412010

ISSUE 2THERMAL INSULATION FOR CHILLED WATERPIPING COPYRIGHT

CONTENTS PAGE

1 SCOPE 22 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 22.1 PIPE OUTSIDE DIAMETER 22.2 INSULATION SECTION LENGTHS 22.3 TOTAL LENGTH OF PIPING 22.4 BEND OR PIPE FITTING DETAILS 22.5 PIPE MATERIAL 22.6

PIPE JOINT DETAILS (FLANGED OR SHOULDERED) 2

2.7 REQUIRED LIFE OF CORROSION PROTECTION 22.8 THE PREVAILING AMBIENT CONDITIONS AFFECTING CORROSION 22.9 PACKAGING REQUIREMENTS. 22.10 PIPES TO BE PRE-INSULATED ON SURFACE OR INSULATION TO BE INSTALLED IN-SITU

UNDERGROUND. 23 DEFINITIONS 24 REQUIREMENTS 34.1 GENERAL 34.2

MATERIALS 3

4.3 INSULATION SYSTEM 44.4 CONSTRUCTION 54.5 DESIGN 55 QUALITY ASSURANCE REQUIREMENTS 75.1 QUALITY MANAGEMENT SYSTEM 75.2 QUALITY PLAN 75.3 INSPECTION 75.4 SAMPLING 76 INSPECTION AND TEST 86.1 TYPE TESTS 86.2 PRODUCTION TESTS 87 MARKING AND PACKING 97.1 MARKING 97.2 PACKING 10APPENDIX A : RELATED DOCUMENTS 11APPENDIX B : RECORD OF AMENDMENTS 11

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1 SCOPE

This specification details the requirements for the thermal insulation of chilled water pipesinstalled underground and covers pre-insulation of pipes on surface and in-situapplications underground.

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

2.1 PIPE OUTSIDE DIAMETER

2.2 INSULATION SECTION LENGTHS

2.3 TOTAL LENGTH OF PIPING

2.4 BEND OR PIPE FITTING DETAILS

2.5 PIPE MATERIAL

2.6 PIPE JOINT DETAILS (FLANGED OR SHOULDERED)

2.7 REQUIRED LIFE OF CORROSION PROTECTION

2.8 THE PREVAILING AMBIENT CONDITIONS AFFECTING CORROSION

2.9 PACKAGING REQUIREMENTS.

2.10 PIPES TO BE PRE-INSULATED ON SURFACE OR INSULATION TO BE INSTALLED IN-SITUUNDERGROUND.

3 DEFINITIONS

ACCEPTABLE/APPROVED : Acceptable to and approved by the Engineer

CSIR MINING TEK : Council fir Scientific and Industrial Research MiningTek

ENGINEER : The Consulting Engineer, Consulting Mechanical andElectrical Engineer of AAC or their appointedrepresentative

INSULATION SYSTEM : Combination of one or more of sleeve, vapour barrierand insulant so providing required properties

INSULANT : Material providing thermal insulation through low heattransfer

NBS : National Building Standards

NES : Naval Engineering Standard (Royal Navy)

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PIPE : Water reticulation pipe

SLEEVE : Outer covering which provides protection to the insulant

UPVC : Unplasticised poly-vinyl chloride

VAPOUR BARRIER : Layer of continuous impermeable material sealing theinsulant

The following terms are defined in the General Conditions of Contract:

AAC, Company, Contractor.

4 REQUIREMENTS

4.1 GENERAL

4.1.1 Insulants produced by the chemical reaction of two or more constituents, whichduring the chemical action produce a water vapour: shall not be injected or cast into aclosed void unless:

4.1.1.1 Provision is made: to vent this moisture from the insulant to ensure that the coefficient ofconductivity specified by the manufacturer is obtained.

This conductivity must be stabilised after the insulation has been used in the conditionsshown in table 5 for a period of 200 hours.

4.1.2 Insulants produced by the chemical reaction of two or more constituents, one ofwhich is an acid, shall not be used as slab stock in voids, or be injected into voids whichhave metallic walls unless the walls are suitably protected against corrosion.

4.2 MATERIALS

4.2.1 Sleeve: the sleeve shall comply with the requirements specified in Table 1.

TABLE 1: SLEEVE REQUIREMENTS

1 2 3

MATERIAL REQUIREMENTS TEST METHOD

UPVC

(See note below)

1. Maximum thickness 3,2mm

2. Impact resistanceminimum value 50 kJ/m

3. Comply with AECISpecification No. 130/S/03or approved equivalent

4. UPVC sleeves must becolour coded blue

DIN 53448

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Steel Minimum thickness 0,3mm

Phoenolic Resin Glassreinforced

See AAC Specification 173/1

Note: Where UPVC sleeved piping is routed closer than 2,0m from fuelling bays, oilstores, 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 inTable 2.

Where pipe insulation is purchased without a mechanical protective sleeve, the vapourbarrier material shall comply with the AAC Specification No 412/9.

TABLE 2: VAPOUR BARRIER REQUIREMENTS

1 2 3

PROPERTY REQUIREMENTS TEST METHOD

Water Vapour 0,2g maximum per m/24h at38C 2% and 90% R.H. 5% R.H.

ASTM E96

4.2.3 Insulant: the insulant shall comply with the requirements specified in Table 3.

TABLE 3: INSULANT REQUIREMENTS

1 2 3

PROPERTY REQUIREMENTS TEST METHOD

Combustibility Pass SABS 0177 Part V

(Modified) CSIR

Test Method

Toxicity Maximum Index of 2 SABS Test Method TI (NES)

Thermal Conductivity 0,05 W/mC Max ASTM C177

Smoke Production SpecificOptical Density Value

Maximum index of 10,0 NBS Smoke Density TestMethod

Min Compressive Strength(Parallel to Rise)

175 kPa

Density Max 200kg/m

4.3 INSULATION SYSTEM

The insulation system shall comply with the requirements specified in Table 4.

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TABLE 4: SYSTEM REQUIREMENTS

1 2 3

PROPERTY REQUIREMENT TEST METHOD CLAUSE

Fire Resistance Pass CSIR Mining Tek/CSIR Fire Lab.Tunnel tests

Thickness of insulant Clause 4.4.2 To be specified byContractor

CSIR Mining Tek Dynamic Test(see Clauses 6.2.8 and 4.4.2)

Thermal Conductivity 0.05 W/m C max ASTM C177

Heat gain Table 6 CSIR Mining Tek Dynamic Test

Distortion (Pre-insulated pipes) 10mm Clauses 6.2.5

Note: The overall length of insulation system on pre-insulated pipes shall allow adequateaccess to flange bolt holes etc.

4.4 CONSTRUCTION

4.4.1 Insulant: shall be homogenous, free of voids and shall occupy all cavities within theprotective sleeve.

4.4.2 Thickness of insulant: shall be such that the heat gain values detailed in Table 6 shallnot be exceeded after ageing and after use for 200 hours in conditions as set out inTable 5.

4.4.3 Water vapour protection: of the insulant shall be such that it is encapsulated in amaterial which complies with the requirements for a water vapour barrier as detailed inTable 2. Where this material is joined, the joint shall exhibit the same characteristics asthe parent material.

4.4.4 Products of organic nature: polyurethane or polystyrene based materials shall not beused.

The density of the insulant: shall not be greater than 200 kg/m3.

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 whentested in accordance with the requirements of Clause 6.2.7.

4.4.6 Glass reinforced organic material: if used as a protective sleeve shall comply with therequirements of AAC Specification 173/1.

4.5 DESIGN

The Contractor shall provide for approval, dimensioned drawings and design calculationsat time of tender response accompanied by an SABS certificate stating that an insulationsystem complying with the design has been tested by SABS and complies with therequirements 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.

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The Contractor shall also provide for approval the methods and materials used for fixing in-

situ 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 2

PARAMETER VALUES

Water velocity

Water Temperature

Pipe diameter range

Pipe wall thickness

Pipe thermal conductivity

Air temperature

Air velocity

1m/s

5C

100 - 300mm

6mm

45W/m C

(Mild steel)

32C

5m/s

Note: If pipes of different thermal conductivity are used this shall be specified by theCompany.

4.5.2 Design performance requirements: maximum heat gain per linear metre of insulatedpipe shall not exceed the value given in Table 6.

Note: Value given is for the combined insulating value of pipe wall, vapour barrier andsleeve and is based on a dry clean sleeve outer surface.

TABLE: 6 HEAT GAIN

1 2 3

PIPE: NOMINAL SIZE(mm)

HEAT GAIN(W/LINEAR m)

TEST METHOD

100

150

200

250

300

14

19

24

29

34

See Clause

6.1.2

4.5.3 Designed maximum outside diameter: of insulation shall comply with the requirementsof Table 7.

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TABLE 7

MAXIMUM INSULATION SYSTEM OUTSIDE DIAMETERS

1 2

NOMINAL PIPE SIZE (mm) INSULATIONS, SYSTEMOUTSIDE DIAMETER (mm)

100

150

200

250300

225

290

350

420470

5 QUALITY ASSURANCE REQUIREMENTS

5.1 QUALITY MANAGEMENT SYSTEM

The requirements of SABS ISO 9001 shall apply. All volitional requirements in SABSISO 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 tocommencement 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 theCompany comply with the requirements of this specification.

The Company's representative shall have access at all reasonable times to those parts ofthe manufacturing facilities engaged in the manufacture of items to this specification. He isauthorised to witness any stage of manufacture, tests and inspection documentation.

The representative is authorised to reject any items not manufactured to the requirements ofthis specification.

All quality costs including SABS certification shall be for the account of the Contractor.

5.4 SAMPLING

5.4.1 Sampling for type testing: shall be as determined by the AAC Consulting EnvironmentalEngineer.

5.4.2 Sampling for production testing: shall be in accordance with the requirements detailedin the approved Quality Plan.

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6 INSPECTION AND TEST

6.1 TYPE TESTS

6.1.1 CSIR Mining Tek tunnel testing

Full scale pipe insulation tests shall be performed on two 200 mm diameter insulatedpipes complete with vapour barriers and external protective sheaths. The pipes shall beinstalled 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 Tekfor 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 thefrequency specified in Table 8.

TABLE 8

SAMPLING PLANS FOR TEST CLAUSE, 6.2

1 2 3

LOT SIZE SAMPLE SIZE DEFECTIVE ACCEPTABLE

3 - 25 3 0

26 - 50 13 0

51 - 150 20 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 Testmethod.

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

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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 thecube and determine the density of the insulant by dividing the mass by the volume. Express

the result in kg/m3. The result shall comply with the requirements of Table 3.

6.2.7 Distortion

Apply a force of 5kN, via a 50 x 50 steel angle positioned at 90o

to the pipe axis, onto theouter 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 shallcomply 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 outsideprotective sleeve, for in-situ type insulation.

For pre-insulated pipes, measure the circumference of the pipe and the outsidecircumference of the protective sleeve of the insulated pipe. Calculate the thickness ofinsulation 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 inTable 6.

6.2.9 SABS 0177 Part V (Modified) CSIR combustibility

The empty sample cradle shall be introduced into the furnace and the temperaturesrecorded for 5 minutes.

When the furnace has reached equilibrium temperature a 40mm x 40mm x 40mm sampleof the test material shall be introduced into the furnace and the temperatures shall berecorded 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 emptycradle 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 MARKING AND PACKING

7.1 MARKING

The outer surface of the insulation system shall be marked as follows.

7.1.1 Logo or name of Contractor

7.1.2 Date of manufacture

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7.2 PACKING

Packing shall provide protection during transit and handling of insulation systemcomponents.

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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 thermaltransmission properties by means of the guarded-hot-plate apparatus

ASTM D304 : Recommended practice for heat ageing of plastics without load

ASTM E96 : Test for water vapour transmission of materials

SABS ISO 9001 : Quality management systems

SABS 0177 : Fire testing of materials, components and elements used in buildings

SABS 0177 Part V : Fire testing of materials, components and elements (Modified) CSIRused in buildings

SABS Method T1 : Determination of the toxicity index of the products of combustion fromsmall specimens of materials

AECI 130/5/03 : Specification for PVC formulation

DIN 53448 : Testing of plastics; tensile impact test

AAC Drawing Y1903 : Cladding

AAC 412/9 : Vapour barrier for use with blanket type insulation for chilled waterreticulation piping

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)

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AAC_SPEC_412010