Debswana Dp 0gs104

DP-GS-104

Document status APPROVED Copyright

ISSUE 2 7 March 2008 Page 1 of 28

Debswana Specification Piping: Specification Requirements for Piping

DP-GS-104



1 SCOPE 4

2 DESIGN 4 2.1 DESIGN CODE 4 2.2 PIPEWORK – GENERAL 4 2.3 MAXIMUM SERVICE LIMITS 5 2.4 THERMAL EXPANSION 5 2.5 JOINT OPTIMIZATION 5 3 MATERIALS 6 3.1 RUBBER LINING 6 3.2 SOLDERED COPPER PIPING 6 3.3 CORROSION PROTECTION 6 3.4 WELDING 6 3.5 THERMOPLASTIC PIPING 6 4 PIPING IDENTIFICATION SYSTEMS 6 4.1 PIPELINE IDENTIFICATION 6 4.2 MARKING OF FABRICATED ITEMS 6 4.3 COLOUR CODING 7 4.4 INLINE EQUIPMENT IDENTIFICATION 7 5 FABRICATION, ASSEMBLY, ERECTION, INSPECTION, EXAMINATION AND TESTING 7 5.1 APPLICABLE CODE OF PRACTICE 7 5.2 DISCLAIMER 7 5.3 NON-DESTRUCTIVE EXAMINATION 7 5.4 TESTING 7 5.5 BOLTING 7 5.6 STORAGE 8 5.7 ACCESS 8 6 DESIGN GUIDELINES 8 6.1 DESIGN CONSIDERATIONS 8 6.2 SLURRY PIPING 9 6.3 PIPING FOR USE WITH OIL, GREASE OR FUELS 9 6.4 CLEARANCES AND ACCESSIBILITY 10 6.5 SCREWED PIPING 10 6.6 FLANGED PIPING 11 6.7 GASKETS 11 6.8 EQUIPMENT CONNECTIONS 11 6.9 INSTRUMENT CONNECTIONS 12 6.10 UTILITY STATIONS 12 6.11 VENTS AND DRAINS 12 6.12 MANUAL VALVES 12 6.13 PIPE SUPPORTS 12

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6.14 BURIED PIPEWORK 13 6.15 PIPE LENGTHS 13 6.16 PIPE SPOOLS 13 6.17 SAFEGUARDING 13 APPENDIX A : RELATED DOCUMENTS 14

APPENDIX B : RECORD OF AMENDMENTS 14

APPENDIX C: PIPELINE CODING SYSTEM EXAMPLE 15

APPENDIX D: PRODUCT CODES AND PREFERRED PIPELINE APPLICATION CODES AND MATERIAL SPECIFICATIONS 18

APPENDIX E: PIPING APPLICATION CODES AND MATERIAL SPECIFICATIONS 19

APPENDIX F: VALVE SELECTION CHART GUIDELINE 27

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1 SCOPE

This specification covers the mandatory requirements for the design, materials, fabrication, erection, cleaning and testing of piping and launders. It excludes piping for dry gravels conveyed pneumatically and recovery piping.

Any conflict between the requirements of this specification, standards, data sheets, drawings or with the conditions set out in the Contract shall be referred to Debswana Diamond Company for clarification before proceeding with the fabrication or erection of the affected parts.

2 DESIGN

2.1 DESIGN CODE

The applicable Code of Practice governing the design, fabrication, assembly, erection, inspection, examination and testing of pipework shall be as given below, supplemented by the additional provisions listed hereunder.

• For process piping: ASME B31.3

• For slurry piping: ASME B31.11

2.2 PIPEWORK – GENERAL • Carbon steel pipe sizes of 32, 65, 90, 125 and 175 nominal diameter in mm shall be

avoided except unless required for special equipment connections or critical transport velocity requirements.

• An allowance for corrosion or erosion of pipes shall be considered and provision made for such where applicable.

• Possible internal build up and encrustation shall be taken into account when determining pressure losses and flow characteristics.

• Unless determined otherwise by design, utility piping shall be a minimum of DN15 in process plant areas, and DN40 for long runs outside plant areas.

• Minimum branch connections shall be DN25 for drains and DN15 for vents, sample points and instrument connections unless otherwise specified.

• Where wafer valves are used, these shall be positioned in straight pipe sections but not immediately against equipment or tank nozzles.

• Piping manifolds directly over equipment must be avoided where possible.

• Pump suction piping shall be designed to facilitate removal for pump maintenance.

• Pipe routes shall take precedence over electric cable routes or access ways. However, access ways shall not be impeded.

• On all thermoplastic piping systems the nominal size reference shall be the outside diameter.

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2.3 MAXIMUM SERVICE LIMITS

The design pressure and temperature for a piping system shall be the maximum arrived at based on the following:

• Design pressure and temperature of the equipment to which it is directly connected.

• Set pressure of the relief device, which protects the system.

• Discharge piping of a centrifugal pump not protected by a relief device shall be designed for 1.3 times the maximum static head of the pump plus the maximum possible suction pressure of the pump.

• All piping entering and leaving the battery limit shall be designed assuming a closed valve at the battery limit.

• After pressure reducing/control valve stations, the pipeline specification shall not be down-rated until after the downstream isolation valve.

• The design pressure shall apply from the pressure source up to and including the last valve before entering equipment rated at a lower pressure.

• Sections of pipelines within a system which can be isolated by valves at either end and which may be subject to a temperature increase in the isolated condition shall be protected by a pressure relief device set at 1.1 times the maximum operating pressure.

• The design temperature and pressure for a piping system shall be given as the most severe, highest and/or lowest, which can be experienced. Refer to Debswana Project Specifications (Climatic Conditions) DP GS 101 J (Jwaneng) and DP GS 101 O (Orapa).

2.4 THERMAL EXPANSION

The effects of thermal expansion or contraction shall be provided in the design in accordance with ASME B31.3.

Provision for these conditions in the design will be based on the maximum and minimum temperatures arising from:

• Extremes of environmental temperature

• Extremes of temperature in the piped fluid

• Start up, shutdown and fault conditions

• Regeneration cycles

• Predictable transient conditions

2.5 JOINT OPTIMIZATION

General requirements unless otherwise specified:

Slurry Piping All sizes - Flanged

Utility Piping UTI DN50 - Screwed

Utility Piping DN65 & above - Butt weld

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3 MATERIALS

3.1 RUBBER LINING

Rubber lining of pipework shall be in accordance with Debswana Project Specification DP GS 109 which includes Debswana Specification 412004.

Rubber lining of pipe spools shall be carried out off-site wherever possible.

Rubber lining for all services shall be 6 mm thick and extended over the face of the flange.

Welding activities on site on rubber lined piping systems shall be restricted to the make up of “Closure Spools” prior to rubber lining. Rubber lining of all closure pieces shall comply with these standards.

3.2 SOLDERED COPPER PIPING

Solderers must follow the procedure set out in the "Code of Practice for Copper Plumbing" issued by the South African Copper Development Association.

3.3 CORROSION PROTECTION

Piping shall be painted in accordance with the applicable CPS132 or CPS137 system as specified in Debswana Project specification DP-GS-105, but subject to a third party design review as required by the Engineer.

Should there be a requirement for buried pipework, corrosion protection should be reviewed by the engineer.

Note: A thorough understanding of any corrosion characteristics of the water/fluid that will be conveyed is required to ensure that pipe material and corrosion protection systems selected adequately suit the application.

3.4 WELDING

Where AWS welding electrodes are specified, equivalent national standards can be used.

3.5 THERMOPLASTIC PIPING

Refer to appendix E

4 PIPING IDENTIFICATION SYSTEMS

4.1 PIPELINE IDENTIFICATION

The typical pipeline coding system to be applied shall be aligned with the example in Appendix C, subject to the approval of the engineer.

4.2 MARKING OF FABRICATED ITEMS

All piping, fittings, flanges, etc. shall be clearly marked for easy identification. Marking shall include pipeline number, drawing number and item number.

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4.3 COLOUR CODING

Shall be in accordance with Debswana specification DS 164051.

4.4 INLINE EQUIPMENT IDENTIFICATION

The coding system adopted shall be provided by the Group C and I Engineer.

5 FABRICATION, ASSEMBLY, ERECTION, INSPECTION, EXAMINATION AND TESTING

5.1 APPLICABLE CODE OF PRACTICE

Unless agreement is specifically made between contracting parties, the latest edition and addenda of the ASME Code B31.3 issued at least 6 months prior to the original contract date for the first phase of activity covering a pipeline installation shall be the governing document until completion of work and initial operation, with the exception that the relevant requirements of local statutory codes will have to be met at all times.

5.2 DISCLAIMER

In so far as this specification is part of a set of standards setting out the piping requirements of a project, the Contractor, in tendering the works, shall be deemed to have satisfied himself with the requirements and conditions set out in the Project Specifications, Standards and Codes of Practice.

5.3 NON-DESTRUCTIVE EXAMINATION

For pipelines containing dangerous commodities, or working at high temperatures (above 40°C) or high pressures (above 40 bar), the minimum NDE (non destructive examination) shall be a random 10% of welds. For the balance, examination shall be limited to visual examinations as detailed in ASME Code B31.3.

5.4 TESTING

All pipes shall be tested on site after erection and cleaning in accordance with ASME Code B31.3. On high pressure systems a hydraulic test to 1,5 times the maximum operating pressure must be carried out. Also refer section 6.17 SAFEGUARDING.

5.5 BOLTING • Bolting shall generally be in accordance with SANS 1700 Grade 4.8 – Black. Should

any other special bolting be required this will be specified on the individual data sheets or drawings.

• All bolts shall be thoroughly lubricated prior to installation and torqueing.

• Bolts shall extend beyond the nut by at least three full threads, but not greater than 7mm.

• One flat or taper washer as required shall be provided under the nut for each bolt.

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5.6 STORAGE

Prior to fabrication and installation on site, all piping material, valves, fittings, etc. must be stored in the designated areas and the method of storage shall be approved by the engineer. Material affected by the weather and/or U.V. rays must be stored under cover. The flanged end of rubber lined pipes and fittings must be protected by a suitable hard cover over the face of the flanges. Material and equipment stored in the open must be adequately protected against the ingress of foreign matter and moisture.

5.7 ACCESS

The contractor must provide all the necessary access scaffolding, working platforms, cranage etc. required to carry out the installation of the piping and equipment.

6 DESIGN GUIDELINES

6.1 DESIGN CONSIDERATIONS

The following aspects shall be considered as part of the design risk assessment in the engineering and routing of piping systems:

• Environmental considerations.

• Economic considerations.

• Conformance to process design requirements.

• Neat, orderly and conventional installation.

• Optimisation and integrity of pipe supporting methods.

• Thermodynamic and water hammer considerations.

• Adequate flexibility, required to satisfy acceptable forces at support points due to expansion, operational and maintenance accessibility.

• Adequate clearances to facilitate maintenance and vehicle access at road crossings.

• Manual valve access.

• Access to control valve sets.

• Conformance to up and downstream straight length requirements, specific to control and measuring devices.

• Make-up of pump suction and discharge piping to facilitate removal or maintenance of pump equipment.

• Adequate provision of vents and drains (process and hydro test).

• Adequate provision of flushing points.

• Access to pipelines subject to frequent maintenance.

• Adequate fall on pipes to prevent settling out of solids.

• Corrosion and abrasion aspects.

• Installation and removal of wafer type valves.

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6.2 SLURRY PIPING • Special design consideration will be given to process slurry and tailing systems, in

particular: Pipe material.

Internal lining of pipe and fittings.

Long radius cold pulled and fabricated bends.

The position of flushing and drain connections.

• Slurry Piping shall be designed and installed with a minimum number of changes in direction to reduce the effects of abrasion and the likelihood of plugging. Where possible, slurry shall flow in a direct line from one item of equipment to another.

• Unless otherwise specified on the material specification data sheet, bends shall be used in place of elbows and the minimum bend radius shall be five pipe diameters (5D) for cold pulled bends and three pipe diameters (3D) for fabricated bends. Consideration shall also be given for the use of hardwall reinforced rubber hose and bends.

• Flushing and drain connections shall be provided as shown on the P&ID’s, on all pump suction lines and at other points in the system where the possibility of plugging exists.

• Slurry lines shall be sloped where indicated on the P&ID and the fall shall not be less than 1 in 100.

• Pump suction lines shall be kept as short as possible and the use of bends shall be avoided.

• When a standby pump is provided in the design, the ‘dead’ piping joining the operating pump and the standby shall be designed to prevent plugging in the ‘dead’ portion of the piping and shall be provided with a flushing connection and drain point.

• Rubber lined suction pipes for slurry feed are not normally preferred. The use of rubber lined suction pipes requires the approval of the client. See Appendix E for specifications.

6.3 PIPING FOR USE WITH OIL, GREASE OR FUELS

For details of the preparation of pipes, tubes and fittings before installation in oil, grease or fuel handling systems refer to Debswana Project Mechanical Erection Specification DP GS-111.

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6.4 CLEARANCES AND ACCESSIBILITY

Equipment, structures and piping shall be arranged to provide clearances as follows:

• The minimum headroom is measured to the bottom of the pipe, flange, and valve handwheel support structure.

Over primary roads 6.5m

Over maintenance roads 4.5m

Over terrain with no motorised traffic 3.1m

• A minimum of 2.2m head clearance to the underside of all overhead piping must be provided over walkways and working platforms as well as a 0.75m horizontal clearance. Valve handwheels and spindles may be located at lower elevations but must be located outside the walkway handrails or else clearly marked to prevent accidental collision.

• Pipe routing around pumps shall be designed to permit free access to at least one side of the pump and motor to facilitate maintenance or removal of either unit.

Valve accessibility: • All manually operated valve handles shall be readily accessible.

• Valve handwheels shall be located 1400 mm above grade or operating platform level where possible.

• Avoid installing valves with the spindle pointing downwards.

• Valves located below ground level shall be installed in a water tight valve box with the handwheel located above ground using extension spindles where necessary.

• Chain wheel operation is not recommended.

• Control valves shall be located at main operating levels with sufficient clearance being provided, both horizontally and vertically, for maintenance

• Control valve sets shall be placed at 450 mm centre line elevation from access walkways.

• Control valves shall be positioned within the correct upstream and downstream straight length requirements in accordance with the manufacturer’s installation requirements.

• Flow indicators or pressure gauges shall be closely located to manual control valves such that they can be clearly seen when operating the valve.

6.5 SCREWED PIPING • Unless otherwise noted, screwed pipe threads shall be in accordance with ISO-R7.

Deviations are acceptable for special connections to proprietary equipment and instruments.

• Where equipment manufacturer standards make unavoidable use of threaded connections, these shall be seal welded.

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• All threaded connections shall be made up with suitable sealing tape; e.g. PTFE, except those to be seal welded. These shall be made up without any tape or compound and after welding, no pipe threads shall be exposed.

• Screwed connections shall be kept to a minimum and must not be used on toxic, caustic or corrosive duties.

6.6 FLANGED PIPING • All process piping shall be flanged in accordance with SANS 1123 unless otherwise

noted.

• Deviations are acceptable for connections to proprietary equipment and outside battery limit interfaces provided that the pressure rating of the flange is equal to or greater than the design rating of the system.

• Flat face flanges shall be used for low-pressure applications below 1 000kPa, connections to cast iron equipment and lined piping systems.

• All flanges shall be installed with the bolt holes straddling the vertical centre line.

• Flanged joints on unlined butt welded systems shall be kept to a minimum.

• Flanged joints shall be used against flanged equipment, in-line equipment, or to break lines where necessary for: Maintenance purposes

Instrumentation

• Flanged joints in corrosive/toxic systems shall not be located over walkways, access platforms, etc., where leakage would be hazardous to personnel. Splash protection covers shall be provided around all flanges in these lines.

• Galvanised CS backing flanges shall be provided on non-metallic piping.

6.7 GASKETS • Full face gaskets shall be used on flat face flanges, and ring type gaskets on raised

face flanges.

• Gaskets shall generally be in accordance with BS 3381 Spiral wound gaskets for steel flanges to BS 1560 where steel flanges are used.

• Polyfin-Based Gaskets to Debswana specification DS 415002 Polyfin-Based Gasket Material may be used for: Flat-faced flange joints in pipelines carrying aqueous fluids at a temperature in

the range 0-50°C and at a maximum working pressure of 2 000kPa.

Flat-faced flange joints in pipelines carrying air at a temperature in the range 0-50°C and at a maximum working pressure of 600kPa.

6.8 EQUIPMENT CONNECTIONS • Connections to equipment shall be designed so that no load is imposed on the

equipment.

• Removable spool pieces shall be fitted to pump suction and discharge piping to facilitate removal or maintenance of pump equipment.

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• Pump suction piping shall be as short as possible, and not smaller in diameter than the pump inlet nozzle. Inlet flow velocity must not exceed 1.5m/s.

• Eccentric reducers on the suction side of centrifugal pumps in liquor systems shall be installed top flat.

• Eccentric reducers on the suction side of centrifugal pumps in slurry systems shall be installed in a bottom flat position.

• All pump suctions against centrifugal pumps shall be provided with a drain valve.

6.9 INSTRUMENT CONNECTIONS

Instrument lines from the process line to the first block valve in the instrument line shall take the same material class as that specified for the process line. The instrument engineer will determine material requirements beyond the block valve.

6.10 UTILITY STATIONS

Where required, hose stations shall be provided with a 25mm connection, except for pressure flushing points, which shall be specified on the P&ID. Sufficient number of stations shall be provided and so located that all areas requiring utilities can be adequately serviced by a hose of 30m maximum length.

6.11 VENTS AND DRAINS • Air release or vent valves shall be located at high points where required on pump

delivery lines.

• Scour or drain valves shall be located at low points where required on pump delivery lines.

• In addition to those vents and drains required for process reasons and shown on the flow sheets, additional vents and drains required for service testing shall be provided during the construction phase.

6.12 MANUAL VALVES • Off-spec flange connections shall be clearly indicated on the piping drawings.

• Screwed valves shall be kept to a minimum.

• The number of different types shall be kept to a minimum.

• On piping transporting abrasive concentrates, special consideration shall be given to the selection of manual valves with regard to flow and shut-off characteristics.

• The effort required to operate valve handwheels under service conditions shall be kept to a minimum. Valves shall be designed to close when the handwheel is rotated in a clockwise direction looking at the face of the handwheel.

6.13 PIPE SUPPORTS • Pipe supports, guides and anchors shall conform to sound engineering practice for

the pipe class and diameter of pipework used.

• Pipe supports shall be designed carry the load caused by the most severe combination of any of the following:

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Mass of pipe and associated equipment.

Mass of operating or testing medium, whichever is the heavier.

Expansion and contraction forces.

Reaction force from safety valves.

Wind loads.

Shock loads (water hammer) caused by sudden closure of valves or pump trips.

Piping sections requiring frequent dismantling shall be provided with permanent supports for the dismantled condition.

Major supporting structures (pipe gantries/bridges/trestles) must be designed and costs estimated by the structural engineer.

Standard pipe clamps, cradles, hangers, U-Bolts, etc., shall be in accordance with BS3974.

All civil supports (sleepers) shall be designed and costs estimated by the civil engineer.

6.14 BURIED PIPEWORK

Should there be a requirement for buried pipework, the corrosion protection should be reviewed with the engineer. Reference should be made to SANS 10121 Cathodic protection for buried and submerged structures.

6.15 PIPE LENGTHS

Pipe lengths are to be shown on piping drawings.

6.16 PIPE SPOOLS • The maximum length of flanged pipe spools shall be as follows:

SANS 62 Heavy UTI DN150 6000mm (Max)

SANS 719 Gr.B DN200 & over 9144mm (Max)

• For the purpose of flushing and hydrostatic testing, pipe spools of the same pipe specification shall be supplied for installation in the position of all inline instruments and special control valves.

6.17 SAFEGUARDING

Where hazardous or toxic contents are present refer to B31.3 Appendix G "Safeguarding" for general considerations. Specialised consultants competent in design of systems carrying hazardous or toxic contents must be consulted.

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APPENDIX A : RELATED DOCUMENTS

ASME SECTION II B31.3 Process Piping

BS 21, ISO R7 Tapered Pipe Threads

DP GS 101 Project Specifications

DP GS 109 Rubber Lining

DP GS 105 Corrosion Protection

DP GS 111 Project Mechanical Erection Specification

DS 164051 Colour Coding of Piping

SANS 1123 Pipe Flanges

SANS 1700 Fasteners

SANS 10121 Cathodic Protection for Buried and Submerged Structures.

DS SPEC 415002 Polyolefin Based Gaskets

APPENDIX B : RECORD OF AMENDMENTS

Issue 0 : Converted from OR2 GS 104 Rev 0

Issue 1 : Updated from DP GS 104 Rev 0

Issue 2 Addition of Appendix F (Valve Selection Guidelines)

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APPENDIX C: PIPELINE CODING SYSTEM EXAMPLE

NOTE. THIS IS A GUIDE ONLY. PROJECT SPECIFIC NUMBERING REQUIREMENTS SHOULD BE DEVELOPED BY THE PROJECT TEAM.

Pipeline identification numbers are made up as follows:-

T G A 150 DS ZP 4163

Plant identification letter T

Location letters for plant section G

Stream designation A

Nominal size of pipeline 150

Product being handled DS (2 digit)

Pipeline material and lining ZP (2 digit)

Area designation 4 (1 digit)

Sequence number of pipeline 163 (3 digit)

1. Plant Identification Letter

Should there be more than one process plant, this letter would be used.

2. Locations

Typical plant section location letters can be taken from the following list.

Location Title

“A” Primary crushing area

“B” Primary scrubbing and screening area

“C” Crushing area

“D” Secondary scrubbing and screening area

“E” Coarse DMS plant area

“F” Fines DMS plant area

“G” Slimes disposal area

“H” Tailings disposal area

“J” Localised services - main plant

“K” Recovery plant area

“L” Sorthouse

“M” Localised services recovery/sorthouse

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3. Stream Designation Letter The following stream codes are as follows:

“X” - Signifies the “mainstream” of the process flow. This covers items which handle the whole of the process flow.

Where any stream splits into two or more parallel streams then piping and equipment will retain the stream parallel number e.g. A, B, C, etc. but will be numbered sequentially in the last coding digit.

Eg. TGA 150 DSZP-4163 and TGA 150 DSZP-4164

4. Pipeline Size

4.1 Steel Pipes The pipeline size, excluding any linings, is the nominal diameter in accordance with ASME Code Section B31.3 expressed in millimetres.

4.2 Plastic Pipes The pipeline size will be the outside diameter of the pipe expressed in millimetres. NB: Care must be taken to determine the I/D of plastic pipes for use in all flow calculations, etc.

4.3 Asbestos-cement Pipes Asbestos cement pipes shall not be used.

4.4 Steel Launders The launder size will be quoted as the internal width, excluding any lining.

5. Product Codes A two letter code will be used to identify the product being handled in the pipeline. See Appendix D.

6. Pipeline Material and Linings A two letter code will be used to identify the material of construction of the pipeline and any special lining. (Also refer note 3,3) See Appendix E.

7. Area Designation Typically, a treatment plant would be split up into areas to facilitate design, construction etc. The area codes would be specified by the project team as required.

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8. Pipeline Sequence Number The pipeline sequence number will be derived on the P & ID's in as logical a manner as possible. Within any plant area (location) the sequence number will be unique and will not be affected by the preceding descriptive codes. Where plant streams exist it will be desirable if similar pipelines in the different streams have sequence numbers which are in a simple series.

e.g. Stream "A" "B" "C" "D"

Pipeline 1 125 135 145 155

Pipeline 2 126 136 146 156

Pipeline 3 127 137 147 157, etc.

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APPENDIX D: PRODUCT CODES AND PREFERRED PIPELINE APPLICATION CODES AND MATERIAL SPECIFICATIONS

PRODUCT CODE PIPELINE PRODUCT PIPELINE APPLICATON CODES AND MATERIAL SPECIFICATION **

PA

IA

Process compressed air

Instrument compressed air

ZP

ZG

RW

DW

PW

Raw untreated fresh water

Domestic water (Potable)

Process water (Clarified)

ZP

ZG

ZP

FW Fire water ZP

WW

SW

CW

EW

Reclaimed water

Sealing water for glands

Cooling water

Effluents, waste, spillage etc.

ZP

ZP

ZP

ZP/YP/P2

GW

GM

Gravel with water

Gravel with FeSi medium

YP

YP/ZH

FS

FD

Ferrosilicon medium - dense

Ferrosilicon medium - dilute

YP

YP/P2

DS

TS

PS

Dilute slurry

Thickened slurry (± 25% solids)

Paste slurry

ZP/P1/ZR

ZS

ZS

FO

HO

LO

Fuel oil

Hydraulic oil

Lubricating oil

YP

YP

YP

RA Reagents, flocculants etc. ZP

**FOR DETAIL, SEE APPENDIX E

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APPENDIX E: PIPING APPLICATION CODES AND MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATION YP MEDIA FeSi Medium - Dilute(FD), FeSi Medium - Dense(FS), Gravel with FeSi(GM), Gravel and water(GW)

Fuel Oil (FO), Hydraulic Oil (HO), Lubricating Oil (LO)

PIPING 15 - 50 NB 80 - 150 NB 200 - 350 NB

Carbon steel to ASTM A 106 B schedule 40, screwed ISO-R7 Carbon steel to ASTM A 106 B schedule 40, ends bevelled Carbon steel to ASTM A 106 B schedule 40, ends bevelled

CONNECTIONS 15 - 50 NB 80 - 350 NB

Wrought carbon steel couplings and unions to BS 1740, screwed ISO-R7 Carbon steel slip-on plate flanges to SANS 1123 Table 1000/3, flat face, material to SANS 1431 Gr 300 WA Flanges to be machined on joint face only

BENDS 15 - 50 NB 80 - 350 NB

Wrought carbon steel elbows to BS 1740, screwed ISO-R7 White cast iron MITAK 1001 or equivalent as per supplier standard dimensions, including 5 times diameter straight length spool piece after bends (where shown on drawings) Disagglomeration pump delivery lines - hoses as detailed below

BRANCHES 15 - 50 NB 80 - 350 NB

Wrought carbon steel tees to BS 1740, screwed ISO-R7 Full penetration fully scarfed set-on tee fabricated from piping specified above (gussetted where indicated on drawings)

REDUCERS 15 - 50 NB 80 - 350 NB

Wrought carbon steel concentric reducers to BS 1740, screwed ISO-R7 Concentric and eccentric, Pump deliveries - Carbon steel fabricated from piping specified above, flanged ends Pump suctions - White cast iron MITAK 1001 or equivalent to BS 2035 - 1966, flanged ends

GASKETS Full face, soft natural rubber (40 Shore hardness), 6mm thick at cast flanges, 3mm thick at other joints HOSES Heavy duty hardwall pulp and slurry hose, (eg Skega or equivalent as approved by the engineer)., working pressure

1000kPa, 9mm liner, cover of age and weather resistant SBR compound, Flanges to SANS 1123 table 1000/3


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MATERIAL SPECIFICATION P1 MEDIA DILUTE SLURRY DS

ITEM SIZE DESCRIPTION SPECIFICATION

PIPING ALL SIZES PE80 PN 12.5b High Density Polyethylene (HDPE) Holstalen GM 5010 SANS 4427(SABS ISO 4427 of 1996)

FITTINGS ALL SIZES PN 12.5b High Density Polyethylene (HDPE) SANS 4427(SABS ISO 4427 of 1996)

MECH JOINTS ALL SIZES HDPE STUB END PE 100 SDR11 C.S. Galvanised backing flange to SANS 1123 Table 1000

SANS 4427(SABS ISO 4427 of 1996)BS1501-151-26A

BENDS ALL SIZES HDPE PE80 PN 12.5b D pulled bends with HDPE stub end and backing flange SANS 4427(SABS ISO 4427 of 1996)

BOLTS ALL SIZES BLACK CS HEX Bolt & Nuts SANS 1700 BOLT GR4.8 - NUT GR 4.0

NOTE:

1) Fittings are to be avoided where possible.

2) Gaskets not required to be used at interface of HDPE joints, unless recommended by the pipe fitting supplier

3) Gaskets to BS 3381 Spiral wound gaskets for steel flanges to BS 1560 to be used at interface of HDPE to steel flanges only.

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MATERIAL SPECIFICATION P2 MEDIA DILUTE SLURRY

RAW WATER DS RW

EFFLUENT/SPILLAGE FERR0SILICON

EW FD


PIPING ALL SIZES PE 80 PN PN08 b wall High Density Polyethylene (HDPE) Holstalen GM 5010 SA SANS 4427 (SABS ISO 4427 of 1996 PE80)

FITTINGS ALL SIZES PE80 PN 12.5b wall High Density Polyethylene (HDPE) SANS 4427(SABS ISO 4427 of 1996 PE 80)

MECH JOINTS ALL SIZES HDPE STUB END PE 100 SDR11 CS. Galvanised backing flange to SANS 1123 Table 1000

SANS 4427(SABS ISO 4427 of 1996 BS 4504)

BENDS ALL SIZES HDPE PE80 PN 12.5 b 3D or less pulled bends with HDPE stub end and backing flange

SANS 4427(SABS ISO 4427 of 1996 BS 4504)


NOTE:


2) Gaskets not required to be used at interface of HDPE joints, unless recommended by the pipe fitting supplier

3) Gaskets to BS 3381 Spiral wound gaskets for steel flanges to BS 1560 to be used at interface of HDPE to steel flanges only.

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MATERIAL SPECIFICATION ZH (Re-inforced Flexible Rubber Hose) MEDIA GRAVEL WITH FeSi

DILUTE SLURRY GM DS


PIPING ALL SIZES Re-inforced soft wall flexible rubber hose for high abrasion resistance CLASS 100 TYPE ‘H’

FLANGES ALL SIZES Built-in revolving flanges – Drilling to SANS 1123 Table 1000 SANS 1123

GASKETS ALL SIZES Gaskets as recommended by the hose fitting supplier


NOTE:


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MATERIAL SPECIFICATION ZP MEDIA Process Air(PA), Cooling Water(CW), Effluent Water(EW), Fire Water(FW), Process Water(PW), Raw Water(RW), Reclaimed

Water(WW), Sealing Water(SG), Dilute Slurry - up to 300 NB(DS), Reagents (RA)

PIPING 15 - 50 NB 80 - 150 NB 200 - 300 NB 350 - 1000 NB

Carbon steel to SANS 62 heavy wall, joint ERW, screwed ISO-R7 Carbon steel to SANS 62 heavy wall, joint ERW, ends bevelled Carbon steel to SANS 719, 4,5mm thick wall, joint ERW, ends bevelled Carbon steel to SANS 719, 6mm thick wall, joint ERW, ends bevelled

CONNECTIONS 15 - 50 NB 80 - 150 NB 200 - 1000 NB

Wrought carbon steel couplings and unions to BS 1740, screwed ISO-R7 Carbon steel slip-on plate flanges to SANS 1123 Table 1000/3, flat face, material to SANS 1431 Gr 300 WA Carbon steel slip-on plate flanges to SANS 1123 Table 1000/3, flat face, material to SANS 1431 Gr 300 WA

BENDS 15 - 50 NB 80 - 150 NB 200 - 500 NB

Wrought carbon steel elbows to BS1740, screwed ISO-R7 5 - piece segmental bends, 3xD minimum radius, fabricated from piping specified above, flanged ends or 3xD radius pulled bends, flanged ends 5 - piece segmental bends, 3xD minimum radius, fabricated from piping specified above, flanged ends

BRANCHES 15 - 50 NB 80 - 1000 NB

Wrought carbon steel tees to BS 1740, screwed ISO-R7 Full penetration fully scarfed set-on tee fabricated from piping specified above (gusseted where indicated on drawings)

REDUCERS 15 - 50 NB 80 - 1000 NB

Wrought carbon steel concentric reducers to BS 1740, screwed ISO-R7 Concentric and eccentric, carbon steel fabricated from piping specified above, flanged ends

GASKETS Full face, fibre reinforced soft rubber insertion, 3mm thick

DP-GS-104




MATERIAL SPECIFICATION ZS MEDIA Thickened Slurry

PIPING 15 - 50 NB 80 - 150 NB 200 - 300 NB 350 - 1000 NB

Carbon steel to SANS 62 heavy wall, joint ERW, screwed ISO-R7 Carbon steel to SANS 62 heavy wall, joint ERW, ends bevelled Carbon steel to SANS 719, 8 mm thick wall, joint ERW, ends bevelled Carbon steel to SANS 719, 10 mm thick wall, joint ERW, ends bevelled

PIPING (above 40bar)

80NB-200NB ASTMA106 Grade B, schedule 40 (8,2 mm wall thickness)

CONNECTIONS (up to 40 bar)

15 - 50 NB80 and above

Wrought carbon steel couplings and unions to BS 1740, screwed ISO-R7 Carbon steel slip-on plate flanges up to 40 bar to SANS 1123 Table 1000/3, flat face, material to SANS 1431 Gr 300 WA

CONNECTIONS (above 40 bar)

50NB-200NB ANSI class 400 slip on flanges rated 60 bar

BENDS 15 - 50 NB 80 - 150 NB 200 - 500 NB

Wrought carbon steel elbows to BS1740, screwed ISO-R7 5 - piece segmental bends, 5xD minimum radius, fabricated from piping specified above, flanged ends or 5xD radius

pulled bends, flanged ends 5 - piece segmental bends, 3xD minimum radius, fabricated from piping specified above, flanged ends

BRANCHES 15 - 50 NB 80 - 1000 NB

Wrought carbon steel tees to BS 1740, screwed ISO-R7 Full penetration fully scarfed set-on tee fabricated from piping specified above (gussetted where indicated on drawings)

REDUCERS 15 - 50 NB 80 - 1000 NB

Wrought carbon steel concentric reducers to BS 1740, screwed ISO-R7 Concentric and eccentric, carbon steel fabricated from piping specified above, flanged ends

GASKETS Full face, fibre reinforced soft rubber insertion, 3mm thick

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APPENDIX E : PIPING APPLICATION CODES AND MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATION ZR

MEDIA Dilute Slurry (Pump Suctions)

PIPING 150

200-400

Carbon Steel SANS 62 Heavy. BE

Carbon Steel SANS 719-B 6mm wt

LINING 150

200-400

Soft rubber lined

FLANGES 150

200-400

SANS 1123

GASKETS 150

200-400

Fibre Reinforced Soft Rubber FF 3mm thk

BOLTS SANS 1700 Gr 4.8/4.0

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APPENDIX E : PIPING APPLICATION CODES AND MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATION ZG

MEDIA Instrument Air, Domestic Water

PIPING 6-40

50-150

200-450

500-1000

Carbon Steel SANS 62 galvanised, screwed to ISO R7,heavy

Carbon Steel SANS 62 galvanised, screwed to ISO R7.medium

SANS 719 GrA, electric resistance welds, plain ended 6mm

SANS 719 GrA, electric fusion welds, plain ended 6mm

FLANGES To 150

From 200

SANS 1123:2007,galvanised 1600/4 f.f.s.b

SANS 1123:2007,galvanised 100/3 f.f

FITTINGS 15-40

50-150

200-450

500-1000

SANS 62, electric resistance welds, hot bent, screwed ends to ISO R7,galv,heavy

SANS 62, electric resistance welds, hot bent, screwed ends to ISO R7 galv, medium

SANS 719 GrA electric resistance welds, fabricated, plain ended,galvanised,6mm

SANS 719 GrA electric fusion welds, fabricated, plain ended,galvanised,6mm

GASKETS Gaskets to BS 3381 Spiral wound gaskets for steel flanges to BS 1560

BOLTS SANS 1700 Gr 4.8/4.0

DP-GS-104



APPENDIX F: VALVE SELECTION CHART GUIDELINE

Media Non-Return Manual On/Off

Manual Proportional

Actuated On/Off

Actuated or Manual Drain

Actuated Proportional

Type Size Type Size Type Size Type Size Type Size Type Size

=<50mm Ball =<50mm Ball =< 50 Compressed

Air >50mm Butterfly >50mm Nil

Butterfly > 50

ESCO Model BFH (CA) 10 - mech condensate trap or

Bekomat Auto Drain Nil

Wafer Check C < 500

Clarified Water

Bermad => 500 (Note 1)

Diaphragm KA =<150mm Diaphragm KA =<150 Diaphragm KA =<150

Rienzi (GSW) =< 50 Raw Water &

Flocculent ? >50

Butterfly or Knifegate E >150mm Butterfly of

Knifegate E >150 Butterfly or Knifegate E >150

Knifegate E All sizes KA Butterfly All sizes

FeSi - Dense Diaphragm KB

FeSi - Dilute Nil

Knifegate ES >50mm Baret Pinch All sizes Knifegate ES All sizes Knifegate ES All sizes Baret

Pinch All sizes

Slurry <10 Bar Diaphragm KB Diaphragm

KB Diaphragm

KB Diaphragm

KB

Slurry <10 Bar

Rubber ball CY All sizes

Knifegate ES Pinch >50mm Knifegate ES

Knifegate ES Pinch >50mm

Slurry >10 Bar Pinch All sizes Pinch

All sizes

Pinch

Slurry >100 Bar

None Ball All sizes

None Ball All sizes Ball

All sizes

None

Diaphragm KB Effluent, Waste & Spillage

Rubber ball CY All sizes

Knifegate ES >50mm Nil Knifegate ES All sizes Knifegate ES All sizes Nil

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P & ID - Valve Legend General Notes

A - KA - Diaphragm - Weir Type (Saunders, see note 2) 1 Or all sizes where multiple pumps deliver into a common manifold.

B - Ball or Globe KB - Diaphragm - Full Bore (Saunders, see note 2) 2

C - Non-return (Spring loaded wafer type) L - Slide Valve 3 Ported Knife Gates - Not normally used due to spillage during

operation.

CB - Non-return - Bermad (Note 2) M - Float Valve 4

CY - Non-return - Rubber Ball N - Needle Valve 5 All actuated valves 50mm NB and below are C & I responsibility.

D - Solenoid P - Plug Valve 6 All actuated valves to be fitted with proximity switches.

E - Knife gate – Standard R - Pressure Relief Valve 7 The above is a guide for selecting valve types. However, the engineer is to use his discretion for each application.

EP - Knife Gate - Ported Gate S - Self Regulating Valve

EQ - Knife Gate - Square orifice T - Condensate Trap - See Act. Valve For Comp Air Above? 8 Orapa generally uses Atval

ES - Knife Gate - Slurry, rubberlined U - Bung Valve

F - Butterfly V - Pinch Valve

G - Gate VB - Baret Pinch Valve (Soes not seal completely) (Note 2)

H - Hydrant – Fire W - Assembly: 25mm KA valve & hose coupling

J - X -

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