ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 1 OF 15

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 3
4.2 Materials 4
4.3 Insulation system 7
4.4 Construction 7
4.5 Design 7

5.0 QUALITY ASSURANCE REQUIREMENTS 9

5.1 Sampling 9

6.0 INSPECTION AND TESTING 9

6.1 Type tests 9

6.2 Production tests 10
6.3 Acceptance certificates and tests 11

7.0 MARKING, PACKING, TRANSPORT AND STORAGE 11

7.1 Marking 11
7.2 Packing 11
7.3 Transport 11
7.4 Storage 11
7.5 Training 12

APPENDIX A : RELATED DOCUMENTS 13

APPENDIX B : RECORD OF AMENDMENTS 14

APPENDIX C : DATA SHEET 15

 ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 2 OF 15

1.0 SCOPE

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

NOTE: THIS DOCUMENT REPLACES ANGLOGOLD ASHANTI SPECIFICATIONS 412/1, 412/9

AND 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

PPROVED : Agreed in writing by the head of the appropriate

AngloGold Ashanti Corporate Office discipline or nominated
representative

S : British Standard

CONTRACTOR : As defined in the General Conditions of Contract

CSIR BOUTEK : Council for Scientific and Industrial Research – Building

Technology

CSIR – MININGTEK : Council for Scientific and Industrial Research – Miningtek

DIN : Deutsches Institute Für Normung

ENGINEER : AngloGold Ashanti Head of Engineering or the nominated

representative

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
 ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 3 OF 15

LDPE : Low density polyethylene

NBS : National Building Standards

NES : Naval Engineering Standard (Royal Navy)

IPE : Water reticulation pipe

PE : Polyethylene

QSP : An AngloGold Ashanti Quality System Procedure

ABS : South African Bureau of Standards

LEEVE : Outer covering which provides protection to the insulant

and vapour barrier

UPVC : Unplasticised polyvinyl chloride

APOUR BARRIER : Layer of continuous impermeable material or compound

covering all sides of the insulation.

4.0 REQUIREMENTS

4.1 General

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

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 the
insulation.

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

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 4 OF 15

4.2 Materials

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

TABLE 1 Protective Cover Requirements

1 2 3
MATERIAL REQUIREMENTS TEST METHOD
UPVC UL 214 CSIR Test
1. Thickness 3.2 mm and non-combustible
(See note below) Method, Modified
2. Comply with AECI Specification No.
130/S/03 or Approved equivalent
4. UPVC sleeves shall be colour coded blue
Steel (Grade 430
Minimum thickness 0.3 mm
stainless steel)
Minimum thickness 0.8 mm for pipes installed
Steel (hot dip in shafts (Grade Z600).
SABS ISO 4998
galvanised) Minimum thickness 0.5 mm for pipes installed
in haulages (Grade Z275)
1. 50% linear LDPE / 50% Polypropyleyne
Rockshield reinforced cloth UL 214 CSIR Test
reinforced cloth 2. Flame retardant added Method, Modified.
3. Minimum thickness 0.8 mm

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

The combination of an UPVC cover and phenolic foam or nitrile rubber insulation is
not acceptable as the toxicity index exceeds 5.
ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 5 OF 15

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

TABLE 2 Water vapour barrier requirements

1 2 3
PROPERTY/
REQUIREMENTS TEST METHOD
MATERIAL
1. 0.0 g maximum per m²/24 h at 38°C dry
bulb ± 2 % and 90 % ± 5 % R.H.
Water vapour 2. The vapour barrier shall cover the entire
transmission (includes insulation section from all sides and be
ASTM E96
bonding/sealing thermally sealed along the seam and not
compounds) glued.
3. Minimum width of thermal seal shall be at
least 6 mm.
SABS 952 – 1985
Tensile strength Not less than 2.24 N/mm
Subsection 5.6
 To breaking point
SABS 952 - 1985
Elongation  In machine direction – not less than 30 %
Subsection 5.6
 In cross direction – not less than 22 %
SABS 952 – 1985
Joint seal (if applicable) Breaking strength – not less than 1.6 N/mm
Subsection 5.6
 In machine direction – not less than 1 120
mN/sheet
BS 782, Part 3,
Tear strength
 In cross direction – not less than 1 870 Method 360B
mN/sheet

UL214 CSIR Test

Combustibility Pass
Method, modified
Vapour barrier A 35 µm aluminium foil (not metalized and Using a dial gauge
construction and guaranteed pinhole free) with a 300 µm (70% for thickness.
minimum thickness of LDPE and 30% Polypropylene) co-extruded Using a microscope
material outer layer and a 35 µm PE inner layer. for pinholes.

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

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 6 OF 15

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

TABLE 3 Insulation requirements

1 2 3
PROPERTY/
REQUIREMENTS TEST METHOD
MATERIAL
UL 214 CSIR Test
Combustibility Pass
Method, modified
Phenolic foam:--------------------0.022 W/m°C
Rock wool:-------------------------0.035 W/m°C ASTM C177 (read
Maximum thermal
Foam Glass (T4):----------------0.039 W/m°C in conjunction with
conductivity at 10°C
Nitrile rubber:----------------------0.040 W/m°C ASTM C518)
Polyethylene foam:--------------0.048 W/m°C
Phenolic foam:-------------------- 60 kg/m3
Rock wool:-------------------------160 kg/m3
Density (allowing a 5%
Foam Glass (T4):----------------120 kg/m3 SABS Method 79
tolerance)
Nitrile rubber(superlon):--------- 77 kg/m3
Polyethylene foam:----------------40 kg/m3
Water vapour For insulation systems that do not use a water
transmission (includes vapour barrier: a maximum of 0.05 g per
ASTM E96
bonding/sealing m²/24 h at 32°C dry bulb ± 2 % and 90 % ± 5
compounds) % R.H.

Note: Any insulation, which physically or chemically decomposes when in contact with
water must be covered with a water vapour barrier.
ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 7 OF 15

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/
REQUIREMENTS TEST METHOD
MATERIAL
SABS Method T1 /
Toxicity index = 5 maximum
NES 713;
Flame spread = pass
CSIR Boutek, Fire
For the complete
Engineering
system as installed
Sciences full scale
(Insulation / water
test
vapour barrier / joint Smoke production max index = pass
CSIR Boutek, Fire
seal / cover)
Engineering
Sciences small
Smouldering combustion = not allowed
scale test
Minimum thickness of
insulation based on Phenolic foam:--------------------15 mm
insulation properties in Rock wool:-------------------------20 mm
SABS approved
table 3, allowable heat Foamglass:------------------------25 mm
measuring tape
gains in Table 6 and Nitrile rubber (Superlon):-------25 mm
conditions specified in Polyethylene foam:--------------30 mm
Table 5
Thermal conductivity As given in table 3 ASTM C177

Note: The overall length of insulation system on pre-insulated pipes shall allow adequate access
to 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 the
insulation is encapsulated in a material which complies with the requirements of a water vapour
barrier 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.
 ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 8 OF 15

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 5°C
Pipe diameter range 100 mm – 300 mm
Pipe wall thickness 6 mm
Pipe thermal conductivity 45 W/m°C (mild steel)
Air temperature 32°C dry bulb
Air velocity 5 m/s

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

4.5.2 Design performance requirements: The maximum heat gain per linear metre of insulated pipe
shall 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 HEAT GAIN
TEST METHOD
(mm) (W/linear m)
100 17
150 25
200 32 See Clause 6.1.2 of
250 39 this specification
300 45
ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 9 OF 15

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

TABLE 7 Maximum insulation system outside diameters (including sleeve)

1 2
NOMINAL STEEL PIPE SIZE INSULATIONS SYSTEM OUTSIDE
(mm) DIAMETER (mm)
100 225
150 290
200 350
250 420
300 470

1 2
INSULATIONS SYSTEM OUTSIDE
NOMINAL uPVC PIPE SIZE (mm)
DIAMETER (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 Occupational
Environment.

Sampling for production testing shall be in accordance with the requirements detailed in the
Approved 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 tests
shall be performed on two 200 mm diameter insulated pipes complete with vapour barriers, bonding
and external protective cover. The pipes shall be installed in parallel.
 ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 10 OF 15

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 2 3
DEFECTIVE
LOT SIZE SAMPLE SIZE
ACCEPTABLE
Up to and including 25 3 0
26 – 50 5 0
51 - 150 8 0
Extracted from BS 6001 AQL 6.5)

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

6.2.2 Toxicity: Toxicity shall be tested in accordance with the requirements of SABS Method T1 (NES
713).

6.2.3 Conductivity: The conductivity of a sample of the insulation shall be tested according to ASTM
C177.

6.2.4 Water vapour transmission: The water vapour transmission values of the water vapour barrier
shall 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 in
accordance 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, Method
360B.

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. Calculate
the volume of the cube 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.

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

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 11 OF 15

For pre-insulated pipes, the circumference of the pipe and the outside circumference of the
protective 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 the
insulation 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 and
permanently marked on the insulation. The batch number shall give the date of manufacture and
the run number.

Additional testing shall be performed as determined by the Manager Occupational Environment or

his representative(for example thickness tests, conductivity, vapour barrier composition, etc.). These
additional tests will be for AngloGold Ashanti’s account. If the insulation does not pass one of the
test, all delivered insulation shall be taken back by the supplier and AngloGold Ashanti shall be
refunded 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 the
following 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 a
reinforced 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 to
the insulation system.

Damaged items will not be accepted from the Contractor.

7.4 Storage

Pipes shall be stored so that damage to the insulation system by mechanical means or by adverse
weather conditions is prevented.
ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 12 OF 15

7.5 Training

Awareness training shall be given for the transportation, storage, installation and maintenance of
the insulation system offered, by the Contractor.
ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 13 OF 15

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 thermal
transmission properties by means of guarded-hot-plate apparatus

ASTM C518 : Test method of steady-state heat flux measurements and

thermal 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 stock
consumable items

ASTM D304 : Recommended practice for heat ageing of plastics without

load

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 Fire

Engineering 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 in

buildings

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
ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 14 OF 15

APPENDIX B : RECORD OF AMENDMENTS

Issue 3 : Tables 1, 2, 4 amended

Clauses 4.5, 7.3 amended
Clause 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 amended

Clauses 4.1, 4.2.1, 4.4.1, 4.5, 7.1, 7.2, amended
Clauses 6.1.2, 4.4.5 removed
Appendix C amended
(C Hegermann 2002-09-25)
ANGLOGOLD ASHANTI SPECIFICATION

THERMAL INSULATION SYSTEM FOR CHILLED WATER

PIPING
412/10 ISSUE 4
COPYRIGHT ANGLOGOLD ASHANTI 2002 APPROVED 2002-10-04 PAGE 15 OF 15

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

CONFORMANCE TO SPECIFICATION 412/10 Issue 4

1 2 3 4
SUPPLIER
COMPONENT REQUIREMENTS TEST METHOD CONFORMANCE
Yes or No?
1. UL 214
CSIR Test
As per table 1 of Spec 412/10 Method,
Protective Cover
Issue 4 modified
2. SABS ISO
4998
1. ASTM E96
2. UL 214
Water vapour As per table 2 of Spec 412/10
CSIR Test
barrier Issue 4
Method,
modified
1. UL 214
CSIR Test
Method,
modified
2. ASTM C177
As per table 3 of Spec 412/10 (in
Insulation
Issue 4 conjunction
with ASTM
C518)
3. ASTM E96
4. SABS
Method 79
1. SABS
Method T1 /
NES 713
Insulation As per table 4 of Spec 412/10 2. CSIR, Full
System Issue 4 scale fire
test
3. CSIR, Small
scale test
1. SABS
approved
As per table 7 of Spec 412/10
Installed sizes measuring
Issue 4
tape