AGA_SPEC_412010

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412/10 ISSUE 4PAGE 1 OF 15

ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATERPIPING

COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04

CONTENTS PAGE

1.0 SCOPE 2

2.0 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2

3.0 DEFINITIONS 2

4.0 REQUIREMENTS 3

4.1 General 34.2 Materials 4

4.3 Insulation system 74.4 Construction 74.5 Design 7

5.0 QUALITY ASSURANCE REQUIREMENTS 9

5.1 Sampling 9

6.0 INSPECTION AND TESTING 9

6.1 Type tests 96.2 Production tests 106.3 Acceptance certificates and tests 11

7.0 MARKING, PACKING, TRANSPORT AND STORAGE 11

7.1 Marking 117.2 Packing 117.3 Transport 117.4 Storage 117.5 Training 12

APPENDIX A : RELATED DOCUMENTS 13

APPENDIX B : RECORD OF AMENDMENTS 14

APPENDIX C : DATA SHEET 15

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1.0 SCOPE

This specification details the requirements for the thermal insulation of chilled water pipes includingflanges, valves and other fittings installed underground, and covers pre-insulation on surface andin-situ applications underground.

NOTE: THIS DOCUMENT REPLACES ANGLOGOLD ASHANTI SPECIFICATIONS 412/1, 412/9AND 412/10 (Issue 3).

2.0 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, outside diameter and bolt lengths)

Required life and type of corrosion protection for complete system

The prevailing ambient conditions affecting corrosion

Packaging, transport and storage requirements

Whether pipes are to be pre-insulated on surface or insulation to be installed in-situ

underground

3.0 DEFINITIONS

ANGLOGOLD ASHANTI : AngloGold Ashanti Limited

ASTM : American Society for Testing and Materials

OVED : Agreed in writing by the head of the appropriateAngloGold Ashanti Corporate Office discipline or nominated

representative

: British Standard

RACTOR : As defined in the General Conditions of Contract

CSIR BOUTEK : Council for Scientific and Industrial Research Building

Technology

MININGTEK : Council for Scientific and Industrial Research Miningtek

DIN : Deutsches Institute Fr Normung

ENGINEER : AngloGold Ashanti Head of Engineering or the nominatedrepresentative

INSULANT : Material providing thermal insulation through low heat transfer

INSULATION SYSTEM : Combination of one or more of sleeve, water vapour barrier,sealant and insulant so providing required properties

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LDPE : Low density polyethyleneNBS : National Building Standards

NES : Naval Engineering Standard (Royal Navy)

: Water reticulation pipe

PE : Polyethylene

QSP : An AngloGold Ashanti Quality System Procedure

: South African Bureau of Standards

VE : Outer covering which provides protection to the insulantand vapour barrier

: Unplasticised polyvinyl chloride

UR BARRIER : Layer of continuous impermeable material or compoundcovering all sides of the insulation.

4.0 REQUIREMENTS

4.1 General

Insulation produced by the chemical reaction of two or more components, which during thechemical action produce a water vapour or contain an acid shall not be injected or cast into a closedvoid.

Insulation 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 which have metallic walls unless a vapour barrier covers theinsulation.

The Data Sheet in Appendix C shall be completed and submitted with the tender. If the Data Sheetis not supplied the tender will be disqualified.

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4.2 Materials

4.2.1 Protective cover: A protective cover (made of either UPVC, stainless steel, galvanised steel orrockshield reinforced cloth) shall be located on the external surface of the insulation systems andshall comply with the requirements specified in Table 1.

TABLE 1 Protective Cover Requirements

1 2 3

MATERIAL REQUIREMENTS TEST METHOD

UPVC(See note below)

1. Thickness 3.2 mm and non-combustible UL 214 CSIR TestMethod, Modified

2. Comply with AECI Specification No.130/S/03 or Approved equivalent

4. UPVC sleeves shall be colour coded blue

Steel (Grade 430stainless steel)

Minimum thickness 0.3 mm

Steel (hot dipgalvanised)

Minimum thickness 0.8 mm for pipes installedin shafts (Grade Z600).Minimum thickness 0.5 mm for pipes installedin haulages (Grade Z275)

SABS ISO 4998

Rockshield

reinforced cloth

1. 50% linear LDPE / 50% Polypropyleynereinforced cloth

2. Flame retardant added3. Minimum thickness 0.8 mm

UL 214 CSIR Test

Method, Modified.

Note: Where uPVC or rockshield covered piping is routed closer than 6.0 m fromfuelling bays oil stores, conveyor belts, oil-filled transformers and switchgear,timber supports, etc, external steel cladding shall be applied, see AngloGold AshantiDrawing No. Y1903.

The combination of an UPVC cover and phenolic foam or nitrile rubber insulation isnot acceptable as the toxicity index exceeds 5.

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4.2.2 Water vapour barrier:The water vapour barrier shall comply with the requirements specified inTable 2.

TABLE 2 Water vapour barrier requirements

1 2 3

PROPERTY/MATERIAL

REQUIREMENTS TEST METHOD

Water vapourtransmission (includesbonding/sealingcompounds)

1. 0.0 g maximum per m/24 h at 38C drybulb 2 % and 90 % 5 % R.H.

2. The vapour barrier shall cover the entireinsulation section from all sides and bethermally sealed along the seam and notglued.

3. Minimum width of thermal seal shall be atleast 6 mm.

ASTM E96

Tensile strength Not less than 2.24 N/mmSABS 952 1985Subsection 5.6

Elongation

To breaking point

In machine direction not less than 30 %

In cross direction not less than 22 %

SABS 952 - 1985Subsection 5.6

Joint seal (if applicable) Breaking strength not less than 1.6 N/mm SABS 952 1985Subsection 5.6

Tear strength

In machine direction not less than 1 120

mN/sheet

In cross direction not less than 1 870

mN/sheet

BS 782, Part 3,Method 360B

Combustibility PassUL214CSIR TestMethod, modified

Vapour barrierconstruction andminimum thickness of

material

A 35 m aluminium foil (not metalized andguaranteed pinhole free) with a 300 m (70%LDPE and 30% Polypropylene) co-extruded

outer layer and a 35 m PE inner layer.

Using a dial gaugefor thickness.Using a microscope

for pinholes.

Note: Foam glass and nitrile rubber insulation do not require a vapour barrier as these materialshave a closed cell structure and are not affected when in contact with water.

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4.2.3 Insulation:The insulation shall comply with the requirements specified in Table 3

TABLE 3 Insulation requirements

1 2 3

PROPERTY/MATERIAL


Combustibility PassUL 214CSIR TestMethod, modified

Maximum thermalconductivity at 10C

Phenolic foam:--------------------0.022 W/mCRock wool:-------------------------0.035 W/mCFoam Glass (T4):----------------0.039 W/mCNitrile rubber:----------------------0.040 W/mCPolyethylene foam:--------------0.048 W/mC

ASTM C177 (readin conjunction with

ASTM C518)

Density (allowing a 5%tolerance)

Phenolic foam:-------------------- 60 kg/m3Rock wool:-------------------------160 kg/m3

Foam Glass (T4):----------------120 kg/m3

Nitrile rubber(superlon):--------- 77 kg/m3

Polyethylene foam:----------------40 kg/m3

SABS Method 79

Water vapourtransmission (includesbonding/sealing

compounds)

For insulation systems that do not use a watervapour barrier: a maximum of 0.05 g perm/24 h at 32C dry bulb 2 % and 90 % 5

% R.H.

ASTM E96

Any insulation, which physically or chemically decomposes when in contact withmust be covered with a water vapour barrier.

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4.3 Insulation system

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

TABLE 4 System requirements (for piping and flange covers)

1 2 3

PROPERTY/MATERIAL


For the completesystem as installed(Insulation / watervapour barrier / jointseal / cover)

Toxicity index = 5 maximumFlame spread = pass

Smoke production max index = pass

Smouldering combustion = not allowed

SABS Method T1 /NES 713;CSIR Boutek, FireEngineeringSciences full scaletestCSIR Boutek, FireEngineeringSciences smallscale test

Minimum thickness ofinsulation based oninsulation properties in

table 3, allowable heatgains in Table 6 andconditions specified inTable 5

Phenolic foam:--------------------15 mmRock wool:-------------------------20 mm

Foamglass:------------------------25 mmNitrile rubber (Superlon):-------25 mmPolyethylene foam:--------------30 mm

SABS approved

measuring tape

Thermal conductivity As given in table 3 ASTM C177

Note: The overall length of insulation system on pre-insulated pipes shall allow adequate accessto flange bolt holes to prevent damage during bolt on/off action.

4.4 Construction

4.4.1 Insulant: The insulation shall be homogenous, free of voids and shall occupy all cavities with.

4.4.2 Water vapour protection: Water vapour protection of the insulation shall be such that theinsulation is encapsulated in a material which complies with the requirements of a water vapourbarrier detailed in Table 2. Where this material is joined, it shall be thermally sealed and not glued.

4.4.2 Products of organic nature: Polyurethane or polystyrene-based materials shall not be used.

4.5 Design

The Contractor shall provide dimensioned drawings, completed data sheet (as given in appendix C)and certified test certificates (as required by this specification) with his tender.

The Contractor shall also provide for Approval, the methods and materials to be used for fixing in-situ type insulation to the pipes.

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4.5.1 Calculations: The parameters detailed in Table 5 shall be used for design purposes.

TABLE 5 Calculations parameters (standard at test site)

1 2

PARAMETER VALUES

Water velocity 1 m/s

Water temperature 5C

Pipe diameter range 100 mm 300 mm

Pipe wall thickness 6 mmPipe thermal conductivity 45 W/mC (mild steel)

Air temperature 32C dry bulb

Air velocity 5 m/s

If pipes of different thermal conductivity pipe diameter and wall thickness areused, this shall be specified by the company.

4.5.2 Design performance requirements: Themaximum heat gain per linear metre of insulated pipeshall not exceed the value given in Table 6.

Note: The 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 Calculations parameters

1 2 3

PIPE : NOMINAL SIZE(mm)

HEAT GAIN(W/linear m)

TEST METHOD

100 17

See Clause 6.1.2 ofthis specification

150 25

200 32

250 39

300 45

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4.5.3 Designed maximum outside diameter: The designed maximum diameter of the insulation shallcomply with the requirements of Table 7.

TABLE 7 Maximum insulation system outside diameters (including sleeve)

1 2

NOMINAL STEEL PIPE SIZE(mm)

INSULATIONS SYSTEM OUTSIDEDIAMETER (mm)

100 225

150 290200 350

250 420

300 470

1 2

NOMINAL uPVC PIPE SIZE (mm)INSULATIONS SYSTEM OUTSIDEDIAMETER (mm)

OD ID

105 88.6 216

155 130.8 266

210 177.2 321

250 211.0 361

5.0 QUALITY ASSURANCE REQUIREMENTS

The requirements of QSP 101 shall apply.

5.1 Sampling

Sampling for type testing shall be as determined by the AngloGold Ashanti Manager OccupationalEnvironment.

Sampling for production testing shall be in accordance with the requirements detailed in theApproved Quality Plan.

6.0 INSPECTION AND TESTING

6.1 Type tests

6.1.1 Full scale fire test (CSIR Boutek, Fire Engineering Sciences): Full-scale pipe insulation testsshall be performed on two 200 mm diameter insulated pipes complete with vapour barriers, bondingand external protective cover. The pipes shall be installed in parallel.

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6.2 Production tests

Production tests shall be performed on samples as detailed in the Quality Plan and at the frequencyspecified in Table 8.

TABLE 8 Sampling plans for test Clause 6.2

1 2 3

LOT SIZE SAMPLE SIZEDEFECTIVE

ACCEPTABLEUp to and including 25 3 0

26 50 5 0

51 - 150 8 0

cted from BS 6001 AQL 6.5)

6.2.1 Small scale flame spread: Combustibility shall be tested in accordance with the requirements ofUL 214 CSIR Method, Modified.

6.2.2 Toxicity: Toxicity shall be tested in accordance with the requirements of SABS Method T1 (NES713).

6.2.3 Conductivity: The conductivity of a sample of the insulation shall be tested according to ASTMC177.

6.2.4 Water vapour transmission: The water vapour transmission values of the water vapour barriershall be tested according to ASTM E96.

6.2.5 Tensile strength: The tensile strength shall be tested in accordance with SABS 952-1985 subsection 5.6.

6.2.6 Elongation: The elongation shall be tested in accordance with SABS 952-1985 Subsection 5.6.

6.2.7 Joint heat seal breaking strength: The joint heat seal breaking strength shall be tested inaccordance with SABS 952-1985 Subsection 5.6.

6.2.8 Tear strength: The tear strength shall be tested in accordance with BS 2782, Part 3, Method360B.

6.2.9 Mass: The mass shall be tested in accordance with SABS Method 79.

6.2.10 Thickness: The thickness shall be tested in accordance with SABS 952-1985 Subsection 5.6.

6.2.11 Density of insulant: Remove a cube from an insulated pipe and determine its mass. Calculatethe volume of the cube and determine the density of the insulant by dividing the mass by thevolume. Express the result in kg/m. The result shall comply with the requirements of Table 3.

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6.2.12 Thickness of insulant: The thickness of the insulant shall be measured prior to encapsulation inthe vapour barrier and outside protective sleeve for in-situ type insulation.

For pre-insulated pipes, the circumference of the pipe and the outside circumference of theprotective sleeve of the insulated pipe shall be measured.

6.3 Acceptance certificates and tests

The following tests are required per batch of insulation / insulation system produced:

Small scale flame spread (UL 214 CSIR Method)

Toxicity SABS Method T1 (NES 713)

Conductivity (ASTM C177)

If any of these tests do not pass the specifications, then the batch shall be rejected. When theinsulation is delivered, a batch certificate with acceptable test results, shall be provided to

AngloGold Ashanti before payment can be made. The batch number shall be clearly andpermanently marked on the insulation. The batch number shall give the date of manufacture andthe run number.

Additional testing shall be performed as determined by the Manager Occupational Environment orhis representative(for example thickness tests, conductivity, vapour barrier composition, etc.).These additional tests will be for AngloGold Ashantis account. If the insulation does not pass one ofthe test, all delivered insulation shall be taken back by the supplier and AngloGold Ashanti shall berefunded for insulation which has already been paid for.

7.0 MARKING, PACKING, TRANSPORT AND STORAGE

7.1 Marking

The outer surface of all insulation sections and the water vapour barrier shall be marked with thefollowing information:

The Contractor's name or logo

The Batch number (with the date of manufacture and run number)

7.2 Packing

Packing shall provide protection during transit from the place of manufacture to the underground

installation site. All insulation sections which have water vapour barriers, shall be contained in areinforced bag which will prevent damage during transit.

7.3 Transport

Transport, loading and unloading shall be performed in a manner which will prevent any damage tothe insulation system.

Damaged items will not be accepted from the Contractor.

7.4 Storage

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Pipes shall be stored so that damage to the insulation system by mechanical means or by adverseweather conditions is prevented.

7.5 Training

Awareness training shall be given for the transportation, storage, installation and maintenance ofthe insulation system offered, by the Contractor.

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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 of steady-state heat flux measurements and thermaltransmission properties by means of guarded-hot-plate apparatus

ASTM C518 : Test method of steady-state heat flux measurements andthermal transmission properties by means of guarded-hot-

Plate apparatus

AECI 130/5/03 : Specification for PVC formulation

AngloGold Ashanti Drawing Y1903 : Cladding

AngloGold Ashanti QSP 101 : Quality requirements for minor products and standard stockconsumable items

ASTM D304 : Recommended practice for heat ageing of plastics withoutload

ASTM E96 : Test for water vapour transmission of materials

BS 782 Part 3 Method 360B : Determination of tear strength of sheet and sheeting

CSIR Boutek FireEngineering Sciences Test : Full scale fire test

DIN 53448 : Testing of plastics, tensile impact test

NES 713 (Royal Navy) : Determination of the toxicity index of the products of Combustion from shall specimens of materials

SABS 952 : Polyolefin film for damp-proofing and water-proofing inbuildings

SABS ISO 9001 : Quality management systems

SABS Method 79 : Mass / unit area of conditioned textile fabrics

UL 214 CSIR Method Modified : Fire testing of materials, components and elements

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APPENDIX B : RECORD OF AMENDMENTS

Issue 3 : Tables 1, 2, 4 amendedClauses 4.5, 7.3 amendedClause 7.5 added

Appendix C sleeve, vapour barrier, and system requirements amended(M. Karsten 2001-02-28)

Issue 4: Table 1,2,3,4,6,7 amendedClauses 4.1, 4.2.1, 4.4.1, 4.5, 7.1, 7.2, amendedClauses 6.1.2, 4.4.5 removed

Appendix C amended(C Hegermann 2002-09-25)

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APPENDIX C : DATA SHEET (to be completed as part of the tender document)

CONFORMANCE TO SPECIFICATION 412/10 Issue 4

1 2 3 4

COMPONENT REQUIREMENTS TEST METHODSUPPLIERCONFORMANCEYes or No?

Protective CoverAs per table 1 of Spec 412/10Issue 4

1. UL 214CSIR TestMethod,modified

2. SABS ISO4998

Water vapourbarrier

As per table 2 of Spec 412/10Issue 4

1. ASTM E962. UL 214

CSIR TestMethod,modified

InsulationAs per table 3 of Spec 412/10

Issue 4

1. UL 214CSIR TestMethod,modified

2. ASTM C177(in

conjunctionwith ASTMC518)

3. ASTM E964. SABS

Method 79

InsulationSystem

As per table 4 of Spec 412/10Issue 4

1. SABSMethod T1 /NES 713

2. CSIR, Fullscale firetest

3. CSIR, Small

scale test

Installed sizesAs per table 7 of Spec 412/10Issue 4

1. SABSapprovedmeasuringtape

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AGA_SPEC_412010