H 12

Specification
Standard Engineering Specification

Pipe Work and Valves
Engineering
10 July 2013
100-SP-PI-0001
Standard Engineering Specifications
Page 3 of 236
100-SP-PI-0001_Rev 3
TABLE OF CONTENTS
1. SCOPE .............................................................................................................................. 14
2. LOCATION AND ENVIRONMENTAL CONDITIONS ................................................................. 14
3. CODES, STANDARDS, SPECIFICATIONS AND REGULATIONS .................................................. 14
3.1 Government Acts and Regulations ............................................................................. 14
3.2 Australian Standards .................................................................................................. 15
3.3 International Standards ............................................................................................. 16
3.3.1 British Standards ............................................................................................... 16
3.3.2 American Standards .......................................................................................... 17
3.4 Company Standards, Specifications And Procedures .................................................. 18
4. RELATED DOCUMENTS ...................................................................................................... 19
4.1 Drawings .................................................................................................................... 19
5. ABBREVIATIONS ............................................................................................................... 19
6. GENERAL .......................................................................................................................... 21
6.1 Temporary Services And Mobile Equipment ............................................................... 21
6.2 General Requirements ............................................................................................... 21
6.3 Operating Conditions ................................................................................................. 21
6.4 Items Excluded ........................................................................................................... 21
7. PIPING SERVICE AND CLASSES ........................................................................................... 22
7.1 Fluid Service Definitions ............................................................................................. 22
7.2 Piping Class Summary ................................................................................................ 23
7.3 Line Numbering System ............................................................................................. 24
7.4 Pipe Service And Colour Table .................................................................................... 25
8. PIPING SPECIFICATION ...................................................................................................... 26
8.1 General ...................................................................................................................... 26
8.2 Detailed Design .......................................................................................................... 26
8.2.1 Piping ................................................................................................................. 27
8.2.2 Flanges – General .............................................................................................. 28
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8.2.3 Flanged Connections ......................................................................................... 30
8.2.4 Flanged Joint Gasket and Bolt Torque .............................................................. 31
8.2.5 Threaded Connections ...................................................................................... 32
8.2.6 Slurry Piping ...................................................................................................... 33
8.2.7 Fabrications / Manufacture – General .............................................................. 33
8.2.8 Misalignment Tolerance .................................................................................... 34
8.2.9 Repair Defects ................................................................................................... 34
8.2.10 Pipeline Identification ....................................................................................... 35
8.2.11 Pipe Work Surface Protection ........................................................................... 35
8.2.12 General Requirements for Installation/Erecting/Construction ......................... 37
8.2.13 Pipe Support – General ..................................................................................... 38
8.2.14 Installation of Valves ......................................................................................... 39
8.2.15 Piping for Rotating Equipment .......................................................................... 40
8.2.16 General Storage Requirements ......................................................................... 40
8.2.17 Excavation for Buried Piping ............................................................................. 41
8.2.18 Trench Shoring .................................................................................................. 42
8.2.19 Installing Underground Piping ........................................................................... 43
8.2.20 Buried Pipe Work Protective Coatings .............................................................. 43
8.2.21 Trench Backfilling .............................................................................................. 43
8.3 Aquamine (Victaulic PVC) ........................................................................................... 45
8.3.1 General .............................................................................................................. 45
8.3.2 Assembly ........................................................................................................... 45
8.3.3 Pipe supports ..................................................................................................... 45
8.3.4 Aquamine Piping ‐ Installation/Erecting/Construction ..................................... 45
8.4 Carbon Steel And Stainless Steel Fabricated Piping ..................................................... 47
8.4.1 General .............................................................................................................. 47
8.4.2 Connection to Pipe Systems and Equipment of Dissimilar Metals ................... 48
8.4.3 Pipe Fittings ....................................................................................................... 48
8.4.4 Preparation for Welding – General Requirements ........................................... 48
8.4.5 Welding – General Requirements ..................................................................... 49
8.4.6 Welder Qualification – General Requirements ................................................. 49
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8.4.7 Slip on Flanges ................................................................................................... 49
8.4.8 Socket Weld Pipe Systems ................................................................................ 50
8.4.9 Branch Connections .......................................................................................... 50
8.4.10 Pipe Branch Connection Tables ......................................................................... 50
8.4.11 Cold Bending ..................................................................................................... 54
8.4.12 Mitre Bends ....................................................................................................... 54
8.4.13 Preheat and Heat Treatment ............................................................................ 54
8.4.14 Pipe Supports for Fabricated and Threaded Piping .......................................... 54
8.5 Victaulic Carbon Steel Piping – (Std. Weight & Sch. XS)............................................... 55
8.5.1 IPS & AGS Grooved Piping Systems ................................................................... 55
8.5.2 Pipe/Grooved – Standard Weight & Schedule XS ............................................. 56
8.5.3 Mechanical Couplings for Joining Carbon Steel Pipe ........................................ 56
8.5.4 Gaskets .............................................................................................................. 56
8.5.5 Bolted Branch Outlet ......................................................................................... 56
8.5.6 Expansion Joints ................................................................................................ 57
8.5.7 Fittings ............................................................................................................... 57
8.5.8 Pipe Supports .................................................................................................... 57
8.5.9 Assembly ........................................................................................................... 58
8.6 Victaulic Carbon Steel Piping – Fire Service ................................................................. 59
8.6.1 General .............................................................................................................. 59
8.6.2 IPS Grooved Piping Systems .............................................................................. 59
8.6.3 Pipe (Std. Wt.) ................................................................................................... 60
8.6.4 Mechanical Couplings, Fittings and Adaptors ................................................... 60
8.6.5 Pipe Supports .................................................................................................... 60
8.6.6 Assembly ........................................................................................................... 60
8.7 Mining Hose ............................................................................................................... 61
8.7.1 General .............................................................................................................. 61
8.7.2 Pipe Supports .................................................................................................... 61
8.7.3 Installation/ Erecting/Construction ................................................................... 61
8.8 High Pressure Hose .................................................................................................... 61
8.8.1 General .............................................................................................................. 61
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8.8.2 Installation/ Erecting/Construction ................................................................... 61
8.9 Polyethylene Piping (HDPE) ........................................................................................ 62
8.9.1 General .............................................................................................................. 62
8.9.2 Equivalent Pipe sizes ......................................................................................... 62
8.9.3 Polyethylene Piping Manufacture and Fabrication ........................................... 63
8.9.4 Polyethylene Branch Connection Table ............................................................ 63
8.9.5 Polyethylene Pipe Welder Qualification ........................................................... 64
8.9.6 Polyethylene Pipe Weld Testing ........................................................................ 64
8.9.7 Polyethylene Piping ‐ Installation/Erecting/Construction ................................. 65
8.9.8 Pipe Supports for Polyethylene Piping .............................................................. 67
8.10 Rubber Lined Carbon Steel Piping ............................................................................... 69
8.10.1 General .............................................................................................................. 69
8.10.2 Specification of rubber ...................................................................................... 69
8.10.3 Surface Preparation for Rubber Lining .............................................................. 69
8.10.4 Rubber Application ............................................................................................ 70
8.10.5 Repair of Lining .................................................................................................. 71
8.10.6 Rubber Lined Spool and Component Identification .......................................... 71
8.10.7 External Protective Coating ............................................................................... 71
8.10.8 Storage and Handling of Lined Steel Pipes ........................................................ 72
8.10.9 Rubber Lined Pipe Inspection and Testing ........................................................ 72
8.10.10 Pipe supports ..................................................................................................... 74
8.10.11 Rubber Lined Piping ‐ Installation/Erecting/Construction ................................ 74
8.11 Polyurethane Lined Carbon Steel Piping ..................................................................... 75
8.11.1 General .............................................................................................................. 75
8.11.2 Specification of Polyurethane ........................................................................... 75
8.11.3 Polyurethane Branched Connection Table ....................................................... 76
8.11.4 Surface Preparation for Polyurethane Lining .................................................... 76
8.11.5 Polyurethane Application .................................................................................. 77
8.11.6 Polyurethane Lined Spool and Component Identification ................................ 77
8.11.7 External Protective Coating ............................................................................... 78
8.11.8 Storage and Handling of Lined Steel Pipes ........................................................ 78
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8.11.9 Polyurethane Lined Pipe Inspection and Testing .............................................. 78
8.12 Victaulic Pressfit 316 Stainless Steel Piping ................................................................. 79
8.12.1 General .............................................................................................................. 79
8.12.2 Pipe .................................................................................................................... 79
8.12.3 Couplings, Fittings ............................................................................................. 79
8.12.4 Connection to Pipe Systems and Equipment of Dissimilar Metals ................... 79
8.12.5 Pipe Preparation ................................................................................................ 80
8.12.6 Assembly ........................................................................................................... 80
8.12.7 Pipe Supports .................................................................................................... 80
8.13 Pipe Work Commissioning And Testing ...................................................................... 81
8.13.1 Visual Inspection and NDE Requirements ......................................................... 81
8.13.2 Pressure Test Requirements ............................................................................. 86
8.13.3 Pneumatic Testing – Pneumatic Pipe Work Only .............................................. 88
8.13.4 Test Duration ..................................................................................................... 88
8.13.5 Preparation for Testing ..................................................................................... 89
8.13.6 Test Equipment ................................................................................................. 90
8.13.7 Completion of Testing ....................................................................................... 90
8.13.8 Test Records ...................................................................................................... 90
8.14 Cleaning And Re‐Instatement ..................................................................................... 90
8.14.1 Cleaning ............................................................................................................. 90
8.14.2 Reinstatement ................................................................................................... 91
9. VALVE SPECIFICATION ....................................................................................................... 91
9.1 General ...................................................................................................................... 91
9.2 Valve Numbers ........................................................................................................... 92
9.2.1 Valve Size and Class Designation ....................................................................... 92
9.2.2 Actuated Isolation and Control Valves .............................................................. 93
9.2.3 Manual Valves ................................................................................................... 93
9.2.4 Valve Tag Details ............................................................................................... 93
9.3 Fire Service Valves ..................................................................................................... 94
9.4 Drain And Vent Valves ............................................................................................... 94
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9.5 Isolation Valves .......................................................................................................... 96
9.6 Access To Underground Valves ................................................................................... 96
9.7 Underground Valve Access Protection ........................................................................ 98
9.8 Valve Operators ......................................................................................................... 99
9.8.1 Manual Operators ............................................................................................. 99
9.8.2 Pneumatic Operators – “On/Off” Service ......................................................... 99
9.9 Surface Protection And Identification ......................................................................... 99
9.10 Gland Seal Water Station ........................................................................................... 99
10. DATA SHEETS.................................................................................................................. 101
10.1 Piping Class Data Sheets ........................................................................................... 101
10.1.1 Piping Class A1 – Aquamine ............................................................................ 101
10.1.2 Piping Class C1 – Carbon Steel (Std. Wt.) ........................................................ 103
10.1.3 Piping Class C2 – Carbon Steel (Std. Wt. Victaulic) ......................................... 105
10.1.4 Piping Class C3 – Carbon Steel (Sch. XS.) ......................................................... 107
10.1.5 Piping Class C4 – Carbon Steel, (Sch. XS. Victaulic) ......................................... 109
10.1.6 Piping Class C5 – Carbon Steel (Diesel Oil) ...................................................... 111
10.1.7 Piping Class C5A – Diesel Twin Walled Pipe – 150 .......................................... 113
10.1.8 Piping Class C5B – Diesel Twin Walled Pipe – 300 .......................................... 115
10.1.9 Piping Class C6 – Carbon Steel, (Sch. XS, Slurry) ............................................. 117
10.1.10 Piping Class C7 – (Large Diameter) .................................................................. 119
10.1.11 Piping Class C8 – Carbon Steel (Sch. 80.) ........................................................ 121
10.1.12 Piping Class C9 – Carbon Steel for Oil Services ............................................... 123
10.1.13 Piping Class D1 – Domestic Water .................................................................. 124
10.1.14 Piping Class G1 – Galvanised Carbon Steel (Std. Wt.) ..................................... 125
10.1.15 Piping Class G2 – Galvanised Carbon Steel (Std. Wt. Victaulic) ...................... 127
10.1.16 Piping Class H1 – Mining Hose ........................................................................ 130
10.1.17 Piping Class H2 – High Pressure Hose ............................................................. 132
10.1.18 Piping Class H3 – General Service Hose .......................................................... 134
10.1.19 Piping Class P1 – HDPE, PN 6.3 ........................................................................ 136
10.1.20 Piping Class P2 – HDPE, PN 6.3 ........................................................................ 138
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10.1.21 Piping Class P3 – HDPE, PN8 ............................................................................ 140
10.1.22 Piping Class P4 –HDPE, PN8 ............................................................................ 142
10.1.23 Piping Class P5 – HDPE, PN10 .......................................................................... 144
10.1.25 Piping Class P7 – HDPE, PN 12.5 ...................................................................... 148
10.1.26 Piping Class P8 – HDPE, PN 12.5 ...................................................................... 150
10.1.28 Piping Class P10 – HDPE, PN16 ........................................................................ 154
10.1.31 Piping Class R1 – Carbon Steel, Rubber Lined, Std. Wt. .................................. 160
10.1.32 Piping Class R2 – Carbon Steel, Rubber Lined, Sch. 80 ................................... 162
10.1.33 Piping Class R3 – Carbon Steel, Rubber Lined, (St. Wt. Victaulic) ................... 164
10.1.34 Piping Class S1 – Pressfit Stainless Steel ......................................................... 166
10.1.35 Piping Class S2 – 316 Stainless Steel ............................................................... 168
10.1.36 Piping Class U1 ‐ Polyurethane Lined Carbon Steel Piping, Std. Wt. ............... 170
10.1.37 Piping Class W1 – UPVC (Pressure) ................................................................. 172
10.1.38 Piping Class W2 – UPVC (DWV) ....................................................................... 174
10.2 Valve Data Sheets .................................................................................................... 175
10.2.1 Ball Valves (Data Sheet 1 of 5) ........................................................................ 175
10.2.6 Butterfly Valves (Data sheet 1 of 2) ................................................................ 180
10.2.7 Butterfly Valves (Data Sheet 2 of 2) ................................................................ 182
10.2.8 Diaphragm Valves ............................................................................................ 183
10.2.9 Gate Valves (Data sheet 1 of 5) ....................................................................... 184
10.2.10 Gate Valves (Data Sheet 2 of 5) ....................................................................... 185
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10.2.14 Knife Gate Valves (Data Sheet 1 of 2) ............................................................. 189
10.2.15 Knife Gate Valves (Data Sheet 2 of 2) ............................................................. 191
10.2.16 Non‐Return Valves (Data Sheet 1 of 3) ........................................................... 192
10.2.19 Air Release Valves ........................................................................................... 195
10.2.20 Rotary Disc valve (Slurry / Tailings) ................................................................. 196
10.3 Pneumatics .............................................................................................................. 197
10.3.1 Compressed Air Tubing Fittings ...................................................................... 197
10.3.2 Compressed Air Tubing ................................................................................... 197
10.3.3 Compressed Air Exhaust Silencer .................................................................... 198
10.3.4 Filter Regulator – FR1 ...................................................................................... 199
10.3.5 Auto Drain – AD1 (Compressed Air) ................................................................ 200
10.4 Miscellaneous Items ................................................................................................ 201
10.4.1 Pressure Gauge Assembly – PGC1 (Standard Applications) ............................ 201
10.4.2 Pressure Gauge Connection – PGC2 (Slurry Applications) .............................. 202
10.4.3 Pressure Gauge Connection – PGC3 (Slurry Applications) .............................. 203
10.4.4 Pressure Transmitter Connection – PTC1 (Standard Applications) ................. 204
10.4.5 Pressure Transmitter Connection – PTC2 (Slurry Applications) ...................... 205
10.4.6 Rubber Expansion Joint – EJ1 (Water, Standard Pressure) ............................. 206
10.4.7 Rubber Expansion Joint – EJ2 (Water, High Pressure, Large Dia.) .................. 208
10.4.8 Rubber Expansion Joint – EJ3 (Slurry) ............................................................. 210
10.4.9 Hose Rack ........................................................................................................ 211
10.5 Service Connection Data Sheets ............................................................................... 212
10.5.1 General ............................................................................................................ 212
10.5.2 Service Connection Pipe Supports .................................................................. 212
10.5.3 Service Connection Class – SC1 ....................................................................... 212
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10.5.12 Service Connection Class – FH1 ....................................................................... 230
10.5.13 Service Connection Class –FH2 ........................................................................ 231
Page 12 of 236
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List of Tables
Table 1: Government Acts, Codes and Regulations ........................................................... 14

Table 2: Australian Standards ......................................................................................... 15
Table 3: International Standards ..................................................................................... 16
Table 4: British Standards ............................................................................................... 16
Table 5: American Standards .......................................................................................... 17
Table 6: Company Standards, Specifications and Procedures ............................................. 19
Table 7: Associated Drawings ......................................................................................... 19
Table 8: Abbreviations ................................................................................................... 19
Table 9: Fluid Service Definitions..................................................................................... 22
Table 10: Piping Class/Duty Summary ............................................................................... 23
Table 11: Pipe Service and Colour Table ............................................................................ 25
Table 12: Maximum Deviation for Flange Face Alignment ................................................... 30
Table 13: Carbon/Stainless Steel Flange Bolt Torques ......................................................... 32
Table 14: Linear Dimensional Tolerances for Pipe Fabricated Spools .................................... 33
Table 15: Misalignment Tolerance .................................................................................... 34
Table 16: Pipe Temperature Range Cases .......................................................................... 47
Table 17: Pipe Branch Connections C1, C3, C5, C5A, C5B, C6, G1, S2 .................................... 52
Table 18: Pipe Branch Connections C7 ............................................................................... 52
Table 19: Pipe Branch Connections C8 ............................................................................... 53
Table 20: C9 Branch Connection Table .............................................................................. 53
Table 21: Maximum Recommended Support Spacing for Steel Pipe ..................................... 55
Table 22: Maximum Recommended Support Spacing for Victaulic Jointed Steel Pipe ............ 58
Table 23: Equivalent Polyethylene Pipe Sizes ..................................................................... 62
Table 24: Polyethylene Branch Connection Table ............................................................... 63
Table 25: Pipe Temperature Range Cases .......................................................................... 67
Table 26: Maximum Support Spacing for HDPE Pipe ........................................................... 68
Table 27: U1 Branch Connection Table .............................................................................. 76
Table 28: Piping Class NDE Requirements .......................................................................... 82

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LIST OF APPENDICES
Appendix 1: Installation Details
Page 14 of 236
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1. SCOPE
This specification defines the piping systems and valves along with requirements for shop and
site piping fabrication, and installation and testing for Fortescue Metals Group Limited. It
applies to all Mine, Rail and Port Facilities
It does not address civil drainage, dewatering systems, or hydraulic power system piping.
Piping materials for fluid services not listed in this specification shall be considered as 'special'
and will require individual design for approval by the Principal.
2. LOCATION AND ENVIRONMENTAL CONDITIONS
For all Mines, Railway and Port facility’s location and environmental conditions refer to the site
data requirements datasheet found in document 100-DS-EG-0051.
3. CODES, STANDARDS, SPECIFICATIONS AND REGULATIONS
All plant, equipment, components, materials, workmanship, services and works shall be covered
by the applicable provisions of the latest editions of relevant codes, standards, specifications
and regulations including but not limited to those listed in the following Sections.
3.1 Government Acts and Regulations
Current editions of the relevant statutory provisions of Government Acts, Codes, Standards and
Regulations that apply in the state of Western Australia, including those listed below:
Table 1: Government Acts, Codes and Regulations

Title
Code of Practice for Storing and Handling of Dangerous Goods (2010)
Dangerous Goods Safety Act 2004 (WA)
Dangerous Goods Safety (Storage and Handling of Non-explosives) Regulation 2007
Rail Safety Act 2010 (WA)
Rail Safety Regulations 2011
Environmental Protection (Noise) Regulations 1997
Fuel Standard (Diesel) Determination (2002)
Mines Safety and Inspection Act 1994 (WA)
Mines Safety and Inspection Regulations 1995 (WA)
Occupational Safety and Health Act 1984
Occupational Safety and Health Regulations 1996
Trade Measurement Act 2006
Design, installation and operation of underground petroleum storage systems — code of practice (WA) 2008
Page 15 of 236
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3.2 Australian Standards
Current editions of the relevant Australian Standards, Codes or Publications, including those
listed below:
Table 2: Australian Standards

Document No. Title
AS 1167 Welding and Brazing - Filler Metals
AS 1214 Hot-dip Galvanised Coatings on Threaded Fasteners
AS 1221 Fire Hose Reels

AS 1260 PVC Pipes and Fittings for Drain, Waste and Vent Applications
AS 1345 Identification of the Contents of Piping, Conduits and Ducts
AS 1432 Copper Tubes for Plumbing, Gas Fitting and Drainage Applications
AS 1463 Polyethylene Pipe Extrusion Compounds
AS 1477 PVC Pipes and Fittings for Pressure Applications
AS 1554 Welding of Steel Structures
AS 1572 Copper and Copper Alloys - Seamless Tubes for Engineering Purposes
AS 1579 Arc-welded steel pipes and fittings for water and waste-water
AS 1627.4 Metal Finishing - Preparation and Pre-treatment of Surfaces - Abrasive Blast
Cleaning of Steel
AS 1646 Elastomeric Seals for Waterworks Purposes
AS 1683 Methods of Test for Elastomers
AS 1796 Certification of Welders and Welding Supervisors
AS 1831 Ductile Cast Iron
AS 1940 Storage and handling of flammable and combustible liquids
AS 2027 Abrasion-Resistant Cast Iron
AS 2032 Installation of PVC Pipe Systems
AS 2033 Installation of Polyethylene Pipe Systems
AS 2118 Automatic fire sprinkler systems
AS 2419.1 Fire hydrant installations – System design, installation and commissioning
AS 2419.2 Fire hydrant installations – Fire Hydrant Valves
AS 2441 Installation of fire hose reels
AS 2554 Hose and Hose Assemblies for Air
AS 2566.1 Buried flexible pipelines - Structural design
AS 2566.2 Buried flexible pipelines – Installation
AS/NZS2648.1 Underground marking tape -Non-detectable tape
AS 2700 Colour Standards for General Purposes
AS 2832.1 Cathodic Protection of Metals - Pipes and cables
AS 2885.1 Pipelines - Gas and liquid petroleum - Design and construction
AS 2941 Fixed fire protection installations - Pumpset systems
AS 3500 Plumbing and drainage set
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Document No. Title

AS 3879 Solvent Cements and Priming Fluids for PVC (UPVC) Pipes and Fittings
AS 3990 Mechanical equipment – Steel work
AS 4037 Pressure equipment – Examination and testing
AS 4041 Pressure Piping
AS 4087 Metallic flanges for waterworks purposes
AS 4118 Fire sprinkler systems - Components - Sprinklers and sprayers
AS 4129 Fittings for polyethylene (PE) pipes for pressure applications
AS 4130 PE Pipes, Pressure Applications
AS 4131 Polyethylene (PE) Compounds for pressure pipe and fittings
AS/NZS 4275.0-6 Methods of testing underground marking tape ‐ General introduction and list of methods
AS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles
AS 4792 Hot-dip galvanized (zinc) coatings on ferrous hollow sections, applied by a
continuous or a specialized process
3.3 International Standards
Current editions of the relevant International Standards, including those listed in below:
Table 3: International Standards

Document No. Title
ISO 9001 Quality management systems - Requirements
ISO 1307 Rubber and plastics hoses Hose sizes, minimum and maximum inside diameters,
and tolerances on cut-to-length hoses
3.3.1 British Standards
Table 4: British Standards

Document No. Title
BS 336 Fire Hose Couplings and Ancillary Equipment
BS 1414 Steel Wedge Gate Valves (Flanged and Buttwelding Ends)
BS 1452 Flake Graphite Cast Iron
BS 1868 Flanged Steel Check Valves
BS 1873 Flanged Steel Globe Valves
BS 5150 Cast Iron Gate Valves
BS 5152 Cast Iron Globe and Globe Stop and Check Valve for General Purposes
BS 5154 Copper Alloy Globe, Globe Stop and Check, Check and Gate Valves
BS 5155 Cast Iron and Carbon Steel Butterfly Valves
BS 5156 Diaphragm Valves
BS 5351 Steel Ball Valves
BS 5352 Steel Wedge Gate, Globe and Check Valves 50 mm and Smaller for The Petroleum,
Petrochemical and Allied Industries
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Document No. Title

BS 6374 Part 5: Lining of Equipment with Polymeric Materials for the Process Industries
(Rubber Lining)
BS 6755 Testing of Valves
3.3.2 American Standards
Table 5: American Standards

Document No. Title
ANSI/ASME B1.1 Unified Screw Threads
ANSI/ASME B1.20.1 Pipe Threads, General Purpose (inch)
ANSI/ASME B16.5 Steel Pipe Flanges and Flanged Fittings
ANSI/ASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings
ANSI/ASME B16.10 Face-to-Face and End to-End Dimensions of Ferrous Valves
ANSI/ASME B16.11 Forged Steel Fittings, Socket-Welding and Threaded
ANSI/ASME B16.20 Ring Joint Gaskets and Grooves for Steel Pipe Flanges
ANSI/ASME B16.21 Nonmetallic Gaskets for Pipe Flanges
ANSI/ASME B16.25 Buttwelding Ends
ANSI/ASME B16.28 Wrought Steel Buttwelding Short Radius Elbows and Returns
ANSI/ASME B16.34 Steel Valves, Flanged and Buttwelding End
ANSI/ASME B16.36 Orifice Flanges
ANSI/ASME B18.2.2 Square and Hex Nuts
ANSI/ASME B31.1 Power Piping
ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ANSI/ASME B31.9 Building Services Piping
ANSI/ASME B36.10 Welded and Seamless Wrought Steel Pipe
ANSI/ASME B36.19 Stainless Steel Pipe
ANSI/ASME B46.1 Surface Texture
ANSI/AWWA C-606 Grooved and shoulder joints
API 5L Line Pipe
API 594 Wafer and Wafer-Lug Check Valves
API 601 Metallic Gaskets for Piping
API 602 Compact Carbon Steel Gate Valves
API 607 Fire Test For Quarter-Turn Valves And Valves Equipped With Non-Metallic Seats –
Sixth Edition
ASTM A 53 Pipe, Steel, Black and Hot Dipped, Zinc-Coated, Welded and Seamless
ASTM A106 Standard Specification For Seamless Carbon Steel Pipe For High-Temperature
Service
ASTM A 105 Forgings, Carbon Steel, for Piping Components
ASTM A 135 Standard Specification for Electric-Resistance-Welded Steel Pipe
ASTM A 153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
Page 18 of 236
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Document No. Title

ASTM A 182 Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for
High Temperature Service
ASTM A 193 Alloy Steel and Stainless Steel Bolting Materials for High Temperature Service
ASTM A 194 Carbon and Alloy Steel Nuts for Bolts for High Pressure and
ASTM A 216 Steel Castings, Carbon, Suitable for Fusion Welding, for High Temperature Service
ASTM A 234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated
Temperatures
ASTM A 312 Seamless and Welded Austenitic Stainless Steel Pipe
ASTM A 351 Steel Castings, Austenitic, for High-Temperature Service
ASTM A 395 Standard Specification for Ferritic Ductile Iron Pressure- Retaining Castings for Use
at Elevated Temperatures
ASTM A 403 Wrought Austenitic Stainless Steel Piping Fittings
ASTM A 536 Ductile Iron Castings
ASTM A 790 Seamless and Welded Ferritic/Austenitic Stainless Steel Pipe
ASTM A 795 Standard Specification for Black and Hot-Dipped Zinc-Coated (Galvanized) Welded
and Seamless Steel Pipe for Fire Protection Use
ASTM A 815 Wrought Ferritic, Ferritic/Austenitic, and Martensitic Stainless Steel Piping Fittings
ASTM B 148 Aluminium Bronze Sand Castings
ASTM B 366 Factory-Made Wrought Nickel and Nickel Alloy Welding Fittings
ASTM B 625 UNS N08904, UNS N08925, UNS N08031, UNS N08932, and UNS N08926 Plate,
Sheet, and Strip
ASTM B 677 UNS N08904, UNS N08925, and UNS N08926 Welded Pipe.
ASTM D 1784 Standard Specification for Rigid Poly(Vinyl Chloride) (PVC) Compounds and
Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds
ASTM D 2241 Standard Specification for Poly(Vinyl Chloride) (PVC) Pressure-Rated Pipe (SDR
Series)
ASTM D 3139 Standard Specification for Joints for Plastic Pressure Pipes Using Flexible
Elastomeric Seals
ASTM F 477 Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe
ASTM F 1476 Standard Specification for Performance of Gasketed Mechanical Couplings for Use
in Piping Applications
ASTM F2634 Standard Test Method for Laboratory Testing of Polyethylene (PE) Butt Fusion Joints
using Tensile-Impact Method
ANSI/NSF 61 Drinking Water System Components-Health Effects
ANSI/NSF 14 Plastic Piping System Components and Related Materials
BS 3293 Carbon Steel Flanges (over 24 inches nominal size)
SAE J1273 SAE J1273 Recommended Practices for Hydraulic Hose Assemblies
3.4 Company Standards, Specifications And Procedures
Current editions of the relevant Company Standards, Specifications and Procedures, including
those listed below:
Page 19 of 236
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Table 6: Company Standards, Specifications and Procedures

Document No. Title
100-SP-CI-0003 Standard Engineering Specification for Concrete
100-SP-ST-0001 Standard Engineering Specification for Structural Steelwork Fabrication
100-SP-ST-0002 Standard Engineering Specification for Structural Steelwork Erection
100-SP-ST-0003 Standard Engineering Specification for Protective Coating Systems – Hot Dip
Galvanising
100-SP-ST-0004 Standard Engineering Specification for Protective Coating Systems – Painting
00000-45-00000-PL-QA-0001 Deliverable and Contractor/Vendor Numbering Plan – T45
11098-00000-GN-PL-0004 Equipment Number Plan – T45
100-PR-EG-0004 FMG Coding Library – Type B – Solomon T155
100-SP-EG-0005 Equipment Numbering – Type B – Solomon T155
100-PR-EG-0007 FMG Coding Library – Type C – Beyond 155
100-SP-EG-0006 Equipment Numbering – Type C – Beyond 155
100-DS-EG-0051 Site Data Sheets
4. RELATED DOCUMENTS
4.1 Drawings
This document has references to the following Drawings:
Table 7: Associated Drawings

Document No. Title
CO-00000-DR-PI-0001 Piping General Notes & Drawing List
CO-00000-DR-PI-0013 Service Connection Typical Arrangement & Details
CO-00000-DR-PI-0014 Restriction Orifice & Spectacle Blinds
5. ABBREVIATIONS
Table 8: Abbreviations
Abbreviation Description
ABS Acrylonitrile Butadiene Styrene
API American Petroleum Institute
ANSI American National Standards Institute
AS Australian Standard
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
Page 20 of 236
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Abbreviation Description
BE Bevel Ends
BW Butt Weld
BS British Standard
DN Nominal Diameter (Number)
EFW Electric Fusion Welded
EPDM Ethylene Propylene Diene Modified
ERW Electric Resistance Welded
FF Flat Face
GR Grade
GTAW(TIG) Gas Tungsten Arc Welding (Tungsten Inert Gas)
HDPE High Density Polyethylene
ISO International Standards Organisation
LR Long Radius
MDPE Medium Density Polyethylene
MMA Manual Metal Arc
MSS Manufacturers' Standardisation Society of the Valve and Fittings Industry
NPT National Pipe Thread
P & ID Piping and Instrumentation Diagram
PE Polyethylene
PUR Polyurethane
PN Nominal Pressure (Number) (bar)
ppm Parts Per Million
PTFE Polytetrafluoroethylene
RF Raised Face
RTJ Ring Type Joint
Sch Schedule
SMLS Seamless
SO Slip On
SS Stainless Steel
Std Wt Standard Weight
SW Socket Weld
TIG Tungsten Inert Gas
TP Type
UL Underwriters Laboratories
ULC Underwriters’ Laboratories of Canada
UNS Unified Numbering System for Metals and Alloys
UPVC Unplasticised Polyvinyl Chloride
WN Weld Neck

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6. GENERAL
6.1 Temporary Services And Mobile Equipment
Unless directed otherwise by the Company Representative, this Specification shall be used for
all temporary services.
Pipe work on mobile equipment which is not covered by other standards shall be supplied and
installed in accordance with this Specification but with greater importance given to the effects of
pipe vibration.
6.2 General Requirements
Piping systems shall comply with the data presented within this specification, equipment
datasheets and applicable design standards and reflect the following:
 All materials shall be new and of quality suitable for the purpose.
 Equipment shall be designed to minimise downtime. Where possible, standard ‘off the
shelf’, readily available equipment and components shall be used.
 All designs shall facilitate ease of access for operation, handling, transportation,
installation, adjustment, control, inspection, maintenance and repair.
6.3 Operating Conditions
All major components shall be designed for continuous operation 24 hours per day, 365 days
per year in a hot, dusty, humid, outdoor environment, with a design life of not less than 20
years.
The equipment shall be able to withstand heavy and abrasive dust loads, harsh use by plant
personnel and wash down with hand held pressurised hoses.
The climatic conditions at the sites where the equipment is to be installed and the nature of the
ambient dust are as described by the relevant project specification.
6.4 Items Excluded
The following items are outside the Scope of this Specification:
 High temperature piping above 100°C,
 Steam Piping,
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 Piping for corrosive chemicals,
 High pressure or specialized duty piping,
 Piping system commissioning.
7. PIPING SERVICE AND CLASSES
7.1 Fluid Service Definitions
The following fluid services are defined for the Project by this specification:
Table 9: Fluid Service Definitions

Abbreviation Definition
CW Chilled Water
DO Diesel Oil
EC Engine Coolant
EO Engine Oil
FL Flocculent and coagulant for thickener
FW Water distributed through pipe work for fire protection purposes (e.g. to fire hydrants,
hose reels and sprinklers)
GO Gear Oil
GRL Grease Low Pressure
GW Gland seal water for process pumps
HO Hydraulic Oil
IA Instrument Air – from air compressor and driers
OW Oily Water
PA Plant Air – from air compressor
PO Pressurised supply of potable water for domestic consumption and amenities.
PW Process Water distributed for dust suppression, wash down, including use in the
desand plant
RW Raw (bore) water sourced from groundwater
SE Domestic and other waste streams to sewerage treatment
SH Sodium Hypochlorite
SL Slurry, including desanding and dewatering slurries
SW Saline water (RO plant waste)
TL Tailings slurry from thickener
TO Transmission Oil
WO Waste Oil (made up of other Oils/Grease)
WC Waste Engine Coolant
WW Waste water, treated sewage, ground water runoff, de-oiled water
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Note: Piping designed to AS 2885 may use the listed fluid designations and pipe specification
class; however this Specification of approved pressures and temperatures cannot be relied
upon. Design to AS 2885 MUST BE noted on P&IDs.
7.2 Piping Class Summary
Table 10: Piping Class/Duty Summary
PIPING CLASS and DUTY SUMMARY

Class Piping Material Max. Service ANSI Fluid
Pressure Flange
Class
A1 Aquamine As Listed #150 PO, RW, PW, SW
C1 Carbon steel, (Std Wt.) 1,600 kPa #150 PW, GW, PA, IA, OW,
WW, CW, EC, WC
C2 Carbon steel, (Std. Wt. Victaulic) 1,600 kPa #150 PW, GW, OW, WW
C3 Carbon steel, (Ex. Strong) 2,400 kPa #300 SL, TL
C4 Carbon steel, (Sch. 80 Victaulic) 2,400 kPa #300 SL, TL
C5 Carbon Steel (Diesel Oil), (Std. Wt.) 1,000 kPa #150 DO, EO, GRL, HO, GO,
TO, WO
C5A Diesel Twin Walled Pipe - 150 1,200 kPa #150 DO
C5B Diesel Twin Walled Pipe - 300 4,000 kPa #300 DO
C6 Carbon steel, (Ex. Strong, Slurry) 1,600 kPa #150 SL, TL
C7 Carbon Steel, (Large Diameter) 1,000 kPa #150 * PW
PN16 *
C8 Carbon Steel (Sch 80) 7,500 kPa # 600 TL
C9 Carbon Steel (Oil Services) 1,600 kPa # 150 EO, HO, GO, TO, GRL,
WO
D1 Domestic water 1,000 kPa NA PO, RW
G1 Gal. carbon steel 1,600 kPa #150 PW, GW, PA, IA, FW, OW,
WW
G2 Gal. carbon steel, (Std. Wt. Victaulic) 1,600 kPa #150 PW, GW, FW, OW, WW
H1 Mining hose 700 kPa #150 SL, TL, PW
H2 High pressure hose 3,000 kPa NA GW
H3 General Service Hose 2,000 kPa NA IA, PA, PW, RW
P1 HDPE, PN6.3 (Nom. Above ground) 500 kPa #150 PO, RW, PW, FL, SW,
(PN6.3) OW, WW
P2 HDPE, PN6.3 (Nom. Below ground) 550 kPa #150 PO, RW, PW, SW, OW,
(PN6.3) WW, SL
P3 HDPE, PN8 (Nom. Above ground) 640 kPa #150 (PN8) PO, RW, PW, FL, SW,
OW, WW
P4 HDPE, PN8 (Nom. Below ground) 700 kPa #150 (PN8) PO, RW, PW, SW, OW,
WW
P5 HDPE, PN10 (Nom. Above ground) 800 kPa #150 PO, RW, PW, GW, FL,
(PN10) SW, OW, WW
P6 HDPE, PN10 (Nom. Below ground) 870 kPa #150 PO, RW, PW, GW, SW,
(PN10) OW, WW
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PIPING CLASS and DUTY SUMMARY

P7 HDPE, PN12.5 (Nom. Above ground) 1,000 kPa #150 PO, RW, PW, GW, SL, TL,
(PN12.5) SW, OW, WW
P8 HDPE, PN12.5 (Nom. Below ground) 1,090 kPa #150 PO, RW, PW, GW, SL, TL,
(PN12.5) SW, OW, WW
P9 HDPE, PN16 (Nom. Above ground) 1,280 kPa #150 PO, RW, PW, GW, SL, TL,
(PN16) SW, OW, WW, CW
P10 HDPE, PN16 (Nom. Below ground) 1,390 kPa #150 PO, RW, PW, GW, SL, TL,
(PN16) FW, SW, OW, WW
P11 HDPE, PN20 (Nom. Above ground) 1,600 kPa #150 PO, RW, PW, SL, TL, SW,
(PN20) OW, WW
P12 HDPE, PN20 (Nom. Below ground) 1,600 kPa #150 PO, RW, PW, SL, TL, SW,
(PN20) OW, WW
R1 Carbon steel rubber lined (Std. Wt.) 700 kPa #150 SL, TL
R2 Carbon steel rubber lined (Sch. 80) 2,400 kPa #300 SL, TL
R3 Carbon steel rubber lined (Std. Wt. 700 kPa #150 SL, TL
Victaulic)
S1 Victaulic Pressfit stainless steel 1,600 kPa #150 PO, PA, IA
S2 Stainless Steel 1,600 kPa #150 PO, RW, PW
U1 Polyurethane Lined Carbon Steel Piping 1960 kPa #150, #300 SL, TL
W1 UPVC – Pressure (above/below ground) As Listed #150 SW, OW, WW, SE
W2 UPVC – DWV (Drain, waste, vent) Atmospheric NA SE, WW
*Flange type for Pipe Class C7 is size dependant – refer to Pipe Class C7 Data Sheet
For Sodium Hypochlorite (SH) fluid, vendor nominated piping materials / piping class may be
used. Full details shall be provided to the Principal & included as part of the formal contract
documentation.
7.3 Line Numbering System
All line numbering shall be in accordance with FMG Equipment Numbering Specifications Types
A, B, or C, refer 100-SP-EG-0007, 100-SP-EG-0005, 100-SP-EG-0006 respectively.
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7.4 Pipe Service And Colour Table
Table 11: Pipe Service and Colour Table

Fluid ID Fluid Pipe Identification Colour Colour Code
CW Chilled water Jade G21

DO Diesel oil Golden Tan X53
White (Note 1)
EC Engine Coolant Golden Tan X53
EO Engine Oil Golden Tan X53
FL Floc/Coagulant Black -
FW Fire Water Signal Red R13
GO Gear Oil Golden Tan X53
GRL Grease – Low Pressure Golden Tan X53
GW Gland Seal Water Jade G21
HO Hydraulic Oil Golden Tan X53
IA Instrument Air Aqua B25
OW Oily water Golden Tan X53
PA Plant Air Aqua B25
PO Potable Water Jade* G21
PW Process Water Jade G21
RW Raw (bore) Water Jade G21
SE Waste (sewage) Black -
SH Sodium Hypochlorite Violet P23
SL Slurry Black -
SW Saline water Black -
TL Tailings Black -
TO Transmission Oil Golden Tan X53
WC Waste Engine Coolant Golden Tan X53
WO Waste Oil Golden Tan X53
WW Waste water Black -
*Indicates supplementary colour required to AS1345
Note 1: Refer to Standard Engineering Specification Diesel Storage and Handling 100-SP-ME-
0044 Section 5.3.5 Fixed Transfer Facilities (Pipelines).

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8. PIPING SPECIFICATION
8.1 General
8.2 Detailed Design
Design of pipe work shall be in accordance with this specification, Australian Standards AS
4041, AS 3500, AS 1579, and all other relevant Australian Standards and Regulatory Authority
requirements.
Note: Diesel pipelines between Diesel facilities should be designed to AS 4041 and similar to
pipe work within facilities. This Specification is not intended for AS 2885 design.
All fabrication shall be inspected in accordance with AS 2032, AS 2033, AS 4041, AS 4037 or
ANSI/ASME B31.3 and this specification.
The AS 4041 piping class for the individual Pipe Classes as detailed in data sheets in Section
10.1 are listed in Section 7.2. All associated requirements for each system, as specified in AS
4041, shall be conformed to. Note that when corrosion allowances are exceeded the piping
may no longer comply with AS4041 and the piping shall be repaired or replaced.
The Contractor shall refer to the relevant project site conditions data sheet for ambient
conditions and use temperatures as specified in the applicable sections of this specification for
the different pipe systems in conjunction with temperatures as specified in the individual piping
class data sheets for piping design, particularly in relation to pipe work expansion due to
temperature change.
All fire system pipe work shall be installed in accordance with all applicable Australian
Standards and Regulatory Authority requirements.
No substitution of materials or changes to design details shall be made without the prior written
approval of the Principal. In the event of conflict between Drawings, the Piping and
Instrumentation Diagrams take precedence.
Fabricated fittings of any material, including polyethylene, shall not be used, except in the case
of Pipe Class C7, unless otherwise specified on design drawings or approved by the Principal.
All pipe branches shall have an isolation and drain / vent valve.
Pipe work shall be designed so that the vent and drain valves can effectively perform their
intended function with all pipe work installed in such a manner that it falls towards the various
drain points as detailed in the design with particular attention paid to compressed air pipe
systems.
Pressures indicated in kPa (kilopascal) are gauge values unless noted otherwise.
Page 27 of 236
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Nominal pipe sizes and wall thicknesses shall be specified in millimetres and shall be in
accordance with ANSI/ASME B 36.10 or B 36.19 or AS 4041.
Piping systems for the various water types shall be designed to avoid air entrapment and
appropriately incorporate correctly sized air release devices to ensure against a build-up of
entrapped air.
8.2.1 Piping
Piping materials shall comply with the piping class data sheets contained within this
Specification unless specified otherwise on design drawings or advised in writing by the
Principal. All materials shall be new and free from damage and defects with piping runs
fabricated from standard pipe lengths in the longest possible lengths suitable for transport and
installation. Materials may be rejected by the Principal if found to be not complying with this
Specification.
Unless otherwise advised, design temperatures as per piping class data sheets shall be applied
for pipes full of liquid and operational.
A pipe temperature range of 0º to 90º C shall be applied for all steel pipes for design when
empty during construction and shutdowns, with corresponding empty state temperatures for
Aquamine, HDPE and UPVC pipe as detailed in their respective section of this specification,
Section 8.2.4 for Aquamine, Section 8.8.7 for HDPE and Sections 10.1.34 and 10.1.35 for
UPVC.
Pipe lengths, bend locations etc. shall be adjusted for changes in length due to thermal
expansion and take into account both the operational and empty states during construction and
shut down periods.
Unless otherwise noted or approved by the Principal the following pipe work shall be field run:
 Threaded Services
 Polyethylene (HDPE)
 UPVC
 Carbon steel DN50 or less
 Stainless steel DN50 or less
 Mining hose
 All hydrostatic tested pipe work shall be fitted with high point vents, low point drains
and low point pressure gauges.
 Piping selected for mobile and vibrating equipment shall not work harden.
Page 28 of 236
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 Valves and piping near trafficable areas shall be protected by closely spaced bollards
8.2.2 Flanges – General
Flanged connections shall use flanges conforming to ANSI/ASME B 16.5 for all sizes up to and
including DN600, and AS 4087 for flanges DN700 – DN900, except for the following cases:
 Where dictated by specific valve and component availability and connection details as
approved by the Principal
 As alternatively detailed on design drawings
 For connection to pre-fabricated flanged fire hydrant riser assemblies
Raised face, slip-on flanges shall be used as standard, except in the following cases:
 HDPE pipe systems shall be stub flanges with ANSI backing rings
 UPVC pipe systems shall be stub flanges with ANSI backing rings
 Aquamine pipe systems shall be stub flanges with ANSI backing rings
 Mining hose systems with beaded end swivel flanges and muff couplings shall have
ANSI flat faced flanges
 Fabricated rubber lined pipe systems shall have ANSI flat faced flanges
 Victaulic Pressfit pipe systems shall have raised face ANSI flange adaptors or flat
faced Van-Stone type flanges as detailed by the designer, regardless of mating flange
configuration. Additional care shall be taken when bolting up flange assemblies if
mating flange is not steel or stainless steel construction
 Fabricated carbon steel and stainless steel pipe work flanges mating to UPVC, Mining
Hose and Rubber Lined Pipe systems shall be flat faced flanges
 UPVC, Mining Hose and Rubber Lined Pipe systems with flat faced flanges shall be
used to mate with raised face flanged valves as required, with additional care to be
taken when tightening flange bolts to ensure sound assembly
 Flat face flanges shall be used to mate with “in line” items such as valves, filters and
pumps that have flat face flanges except for HDPE, Aquamine and Pressfit pipe
systems
 When the lining of an “in line” item such as valves, filters and pumps protrudes over
the face of its flanges, the flanges shall be considered as flat faced flanges and the
mating flanges shall be of the flat face slip on type unless mating pipe system is
HDPE, Aquamine or Pressfit, or unless otherwise specified
 Flanges mating with butterfly valves and wafer style non-return valves shall be of the
weld neck or stub flange type, except where Victaulic flanged adaptor nipples or
Page 29 of 236
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flange adaptors are specified in the respective piping classes and/or design drawings,
with either flat face or raised face as specified above
 Weld neck flanges shall be used when a flange is fitted directly to butt weld fittings for
fabricated steel pipe systems
Pressure/temperature ratings of flanged components shall be as per the respective standard.
Carbon steel flanges shall be of the normal to high carbon content class, not low carbon
content, as per ANSI/ASME B 16.5 and AS 4087.
The finish of gasket faces shall be in accordance with ANSI/ASME B16.5 and AS 4087. The
surface of flange gasket faces shall be free from rust, weld spatter, scars, paint, dents, arc
strikes, corrosion pitting, and other imperfections.

Page 30 of 236
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8.2.3 Flanged Connections
All flange connections shall be made using threaded stud bolts and nuts. A minimum of one
and a maximum of three completed threads shall protrude from the nut after completion of
tightening.
The stud bolt length shall be calculated in accordance with ANSI/ASME B 16.5 and AS 4087.
Where spectacle blinds, etc., are installed, the stud bolt length shall be increased by the
thickness of such devices and the extra gaskets. Length of studs of diameter 38mm and larger
shall be provided with one nut thickness longer than normal to permit use of a bolt tensioner.
Bolts, studs and nuts shall be protected by an anti-seize compound. PTFE coated bolts, studs
and nuts are preferred at Port Sites due to proximity to marine environment and use of saline
process wash water.
Unless otherwise indicated on the drawings, the bolt holes of all flanges shall straddle the
vertical.
Gaskets of suitable material for each individual service shall be used as specified in Piping
Class data sheets in Section 10.1.
The maximum angular deviation of bolt holes shall not exceed 1.5 mm measured across the
bolt pitch circle.
The flange faces shall be square to the pipeline in which they are fitted. The maximum
deviation for flange face alignment when measured at flange outside diameter from the design
plane shall not exceed the following, when measured in any radial direction: Misalignment to be
corrected through re-work of piping if required. Installation of piping with excessive ‘cold spring’
is to be avoided.
Table 12: Maximum Deviation for Flange Face Alignment

Pipe Diameter Nominal Maximum Deviation
DN up to 100 mm 1.0 mm
DN 150 mm to 500 mm 1.5 mm
DN 600 mm to 900 mm 2.5 mm
DN 950 mm and over 3.0 mm
Shop fabrication of flanged spool pieces for connection to existing pipe work or equipment shall
have the mating flange tack welded to the spool and an additional allowance of 100 mm of pipe
shall also be provided for correct field fitment.
See Appendix 1 for flange tightening details

Page 31 of 236
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8.2.4 Flanged Joint Gasket and Bolt Torque
The gasket material and thickness for individual flange connections shall be as specified in the
applicable Piping Class for each specific fluid type application.
Where mating flanges are of different pipe classes such as carbon steel to stainless steel or
carbon steel to UPVC etc., the gasket and bolting requirements of the pipe class with the lower
bolt torque shall be used.
Where carbon steel and stainless steel pipe systems connect via flanges, insulating gasket kits
shall be used in line with the specified gasket material in the piping classes with the insulating
gasket kit details to be specified by the gasket Supplier and approved by the Principal on an
individual basis.
When bolting gasketed flanged connections, the gasket shall be uniformly compressed to the
minimum torques as per the applicable bolt torque table in the following sections.
Flanged connections shall be tightened sequentially diagonally opposite in a clockwise or

anticlockwise order so that an even gasket seating results.
Stud bolts of diameter 20mm and larger shall be tightened by torque wrenches or other
tightening methods which result in uniform tightening of the flanges.
Page 32 of 236
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8.1.5.1 Carbon Steel and Stainless Steel Flange Bolt Torques
Table 13: Carbon/Stainless Steel Flange Bolt Torques

Bolt Torque Values for Carbon Steel and Stainless Steel Flanges With:
Klingersil C6327 x 1.5mm Thick IBC Ring Gaskets
PIPE SIZE ASME B16.20 Class 150# 16 Bar ASME B16.20 Class 300#
Operating Max. Hydro. 24 Bar Max. 24 Bar Operating Max. Hydro.
36 Bar Max.
B7/ B16 / 8.8 STUDS B8 / CLASS 2 / 316 STUDS B7/ B16 / 8.8 STUDS
DN80 130 Nm 120 Nm 190Nm
DN100 130 Nm 120 Nm 210 Nm
DN150 230 Nm 200 Nm 230 Nm
DN200 230 Nm 210 Nm 340 Nm
DN250 340 Nm 320 Nm 390 Nm
DN300 350 Nm 330 Nm 580 Nm
DN350 530 Nm 470 Nm 550 Nm
DN400 530 Nm 470 Nm 770 Nm
DN450 740 Nm NA Nm 830 Nm
DN500 750 Nm NA Nm 930Nm
DN600 1000 Nm NA 1400 Nm
NOTE: 1. ANTI-SEIZE COMPOUND MUST BE USED ON NUT FACES AND STUD THREADS
2. B8/316/304 STUDS REQUIRE CAREFUL TENSIONING. TORQUE VALUES SHOWN CAN
BE AS HIGH AS 60% OF THE STUD/BOLT YIELD.
8.1.5.2 Aquamine, HDPE, UPVC, Rubber Lined Mining Hose and Rubber Lined Carbon
Steel Pipe System Flange Bolt Torques
Bolt torques for Aquamine, HDPE, UPVC, Rubber Lined Mining Hose and Rubber Lined Carbon
Steel Pipe System flanged connections shall be in accordance with each pipe system and
gasket manufacturer’s recommendations.
8.2.5 Threaded Connections
All pipe threads shall be NPT form, including instrument connections, unless otherwise stated,
or when dealing with water services, which should be BSB form.
Schedule 80 pipe shall be used for all threaded pipe work as specified on applicable Pipe Class
Data Sheets.
Inside ends of threaded pipes shall be deburred by reaming.
All threaded connections shall be gauge-checked or chased after galvanising.

Page 33 of 236
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Threaded joints in piping system shall be made up using PTFE gas grade pipe tape or thread
seal compound installed on the male thread. A check on the compatibility of thread seal
compound with plastic piping should only conducted prior to use of thread seal compound on
plastic piping. e.g. Loctite thread seal compound is not compatible with many types of plastic
8.2.6 Slurry Piping
Piping shall be designed to ensure ready access to sections subject to rapid wear.
All slurry pipes shall have scour valves installed as specified on the drawings.
Where flexible pipe is used, continuous support and securing against uplift and sideways
movement is required while providing provision for expansion of pipe work.
Where slurry pipes are required to pass under road ways or similar, it shall be located in a load
supporting culvert of approved design. Sufficient access shall be allowed around the culvert to
allow disconnection at both ends and withdrawal of the underground section of the slurry line.
8.2.7 Fabrications / Manufacture – General
Work shall be carried out in accordance with the applicable standards, codes, regulations and
good engineering practice by qualified trade’s persons.
Methodology statement for carrying out fabrication shall be submitted to the Principal for
approval.
The work shall be properly documented and records prepared and continuously updated as
necessary, for the proper execution and control of fabrication and installation, in accordance
with this specification.
All materials shall be in accordance with this Specification and the piping class specified.
Procedures and documentation for the control, reporting and recording of spool fabrication shall
be submitted to the Principal for approval prior to commencement of the work.
The linear dimensional tolerances for pipe fabricated spools shall be as follows:
Table 14: Linear Dimensional Tolerances for Pipe Fabricated Spools
DESCRIPTION LINEAR TOLERANCE
Length Less than 1.5 m Length 1.5 m and Longer
End to End ± 1.5 mm ± 3.0 mm

Centre to End
Centre to Flange Face
Flange Face to Flange Face
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100-SP-PI-0001_Rev 3
These tolerances apply to each stated drawing dimension and are not cumulative.
8.1.8.1 Stainless Steel Pipe Work
All stainless steel pipe work shall be fabricated in compliance with the relevant standards and
accepted good work practices.
Connection of Piping Class S2 stainless steel to other piping systems and equipment, such as
tanks and pumps, of dissimilar metals that may induce galvanic corrosion shall be via an
insulated connection as specified in the S2 Piping Class data sheet in section 10.1.33.
Direct contact between carbon steel and stainless steel is not permitted. Tools containing
carbon steel and grinding discs containing carbon steel particles shall not be used on stainless
steel.
Tools used for fabrication of stainless steel shall be clearly identified.
Tools to be used only for fabrication of stainless steel piping and piping components shall be
stored separately to avoid accidental switching with tools previously used on carbon steel
fabrication work.
8.2.8 Misalignment Tolerance
All piping fit-ups shall be subject to the following bore misalignment tolerance.
Table 15: Misalignment Tolerance

Nominal Pipe Size Misalignment
DN 150 and smaller 1.0 mm
DN 200 - 300 2.0 mm
DN 350 and larger 2.5 mm
Note: Misalignment should be minimised wherever possible by rotating the pipe/fitting for best
fit and/or by grinding the bore as required.
8.2.9 Repair Defects
Repairs to welded joints, defective or damaged pipe fittings or any other pressure part shall not
be carried out without written approval of the Principal and shall be shown as a hold point in the
ITP.
Repair procedures shall be approved by the Principal prior to commencement of work.
If repairs or modifications are carried out after heat treatment has been completed, the areas
affected by the repair or modification shall be heat treated again.
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8.2.10 Pipeline Identification
Pipe line identification shall be in accordance with AS 1345 and AS 2700.
All piping (regardless of piping class or coating requirements) shall be identified with colour
coding, product identification and flow direction indication using bands and pipe markers in
accordance with Section 7.4 and AS 1345.
Bands shall not be less than 375mm long and shall fully encircle the pipe. All identification
markings shall be placed at intervals of not less than 8m on straight runs and adjacent to all
junctions, branches, valves, services, appliances, bulkheads, wall penetrations and the like. An
exception will be for uninterrupted lengths of external services (such as in pipe racks) visible
along their length where spacing of the identification shall not exceed 50m. Identification
markings shall be placed such that they are clearly visible from the normal access point to the
pipe in question.
In addition to the above, the contained fluid shall be identified by words. The words to be used
shall be those listed in Section 7.4 as “Fluid”. Colouring shall be the same as for the pipeline
numbers. The description shall be placed on the pipelines immediately next to each pipeline
number.
Line identification numbers shall be as shown on the P&ID and shall be black or white to
contrast with the background colour. Height of numbers shall be half the pipe diameter for
pipes DN 150 and smaller and 75 mm high for pipes greater than DN 150.
Flow direction arrows shall be the same colour as the line identification numbers.
On pipe runs, the identification on different pipelines shall be within 500mm of each other.
8.2.11 Pipe Work Surface Protection
8.1.12.1 General
Requirements for surface protection will depend upon the site and area location that the piping
is to be installed.
Surface protection shall be in accordance with details specified in the relevant sections of this
specification and Standard Engineering Specification Protective Coating Systems - Painting
100-SP-ST-0004. The Manufacturer’s standard surface treatment, appropriate to the site
conditions, may be used where it equals or exceeds the requirements of the Standard
Specification when using prefabricated carbon steel piping systems.
Surface protection paint shall not be applied to:
 Stainless steel piping,

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 Non-metallic piping (hoses, HDPE and UPVC),
 Galvanised piping,
 Copper piping
8.1.12.2 Galvanised Piping
Galvanised piping and fittings DN 80 and larger shall be fabricated as flanged spools then hot
dipped galvanised in accordance with Standard Specification 100-SP-ST-0003.
Pipe spools shall be pressure tested prior to galvanising.
Pipe fittings shall be abrasive blasted internally prior to fabrication and galvanising. Pipe bends
shall be stress relieved prior to galvanising.
Pipe and fittings DN 50 and below shall be supplied galvanised with screwed ends in
accordance with this specification and shall be site run.
If any modifications are required to galvanised spools DN 80 and over during installation, the
spool shall be modified and hot dipped galvanised again. For minor modifications and repairs,
the spool may be cold galvanised. Procedure for cold galvanising shall be submitted for the
Principal’s approval and shall be a hold point.
8.1.12.3 Victaulic Pipe Work Protective Coatings
Victaulic pipe, fittings and couplings shall be provided with Victaulic’s standard alkyd enamel
finish or hot dip galvanized finish to ASTM A-153 in place of the requirements of Standard
Specification 100-SP-ST-0004.
Pipe purchased pre-cut and grooved shall be supplied with sound protective coating to the
required Victaulic specification with caution taken to protect pipe protective coatings from
damage during transport and handling.
Pipe that is site cut to length and grooved shall have the protective coating repaired as required
in line with Victaulic product recommendations and/or Standard Specification 100-SP-ST-0004.

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8.2.12 General Requirements for Installation/Erecting/Construction
All piping shall be installed in accordance with the drawings. Flanges or unions shall be
installed to allow installation, removal or maintenance of equipment or valves without
dismantling pipe or steelwork forming part of an adjacent system.
Fabrication of steel piping at Site shall comply with the provisions of AS 4041 and AS 1579.
Stud bolted flange joints shall be made up with the gasket specified for the service in the
Pipeline Gasket Specification; damaged gaskets or gasket compounds shall not be used.
Anchors and expansion joints shall be installed at locations shown on Drawings. When anchors
are being installed, freedom of the expansion joint to have full movement shall be maintained.
Distribution lines and pilot lines shall be taken off the top of main distribution headers.
Modifications to pipe routing may be necessary at site to avoid interference. These

modifications shall be carried out in accordance with the applicable standards in a neat and
workmanlike manner and shall be reflected on ‘as-built’ drawings.
Straight run pipe shall not be pulled through the pipe racks.
Extreme care shall be taken during handling and erection of expansion joints. Shipping rods
shall remain in place until erection is complete but must be removed immediately after the
expansion bellow is installed. Note that some bellows are fitted with restraining rods that are
not meant to be removed, but to limit the extension and bending of the joint.
A straight run of pipe shall contain the minimum number of welds. The use of off-cuts in straight
piping runs shall be avoided. Piping butt welds shall be spaced a minimum of 50 mm or four
times the thinnest wall thickness measuring between the heat affected zones, whichever is
greater.
Cold springing or forcing of piping for the purpose of joint make up is not permitted unless
specified on the drawings.
Misalignment beyond acceptable tolerances in straight pipe runs shall not be permitted. Seam
orientation of welded straight pipe and pier to fittings shall be such that at circumferential welds,
the longitudinal welds shall be staggered over the top of the centreline, preferably 30º left and
30º right of the centre line. The minimum distance between the staggered joints shall be 50 mm
or six times the thinnest pipe wall thickness measured between heat affected zones, whichever
is greater. Care shall be taken to ensure that longitudinal welds clear branch connections.
Pipes passing through concrete walls or floors shall not be cast in. Pipe shall be passed
through cast in sleeves or standard weight pipe having an internal diameter large enough to
give 12 mm radial clearance to the passing flange, and shall have a light infill if air passage is to
be restricted.
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Where pipe work passes through chequered plate floors and grid mesh, a 75 mm high collar
having an internal diameter large enough to give minimum 25 mm clearance to passing flange
shall be welded to the chequered plate/mesh to prevent chafing and promote safety.
In slurry service, pipes shall be flanged at least every six (6) metres unless specified otherwise
with all fittings in the slurry service to be flanged or Victaulic type fittings.
A methodology statement shall be provided for Installation/Erecting/Construction of piping to the

Principal for approval.
8.1.13.1 Stainless Steel Piping
Special precautions shall be taken during stainless steel piping erection in close vicinity of
carbon steel piping. Direct contact between stainless steel and carbon steel is not permitted.
Carbon steel blinds, spades, caps, nuts, bolts and washers shall not be used for stainless steel
pipe and components.
Steel wire slings shall not be used for handling and transportation of stainless steel pipes,
canvas or nylon slings shall be used.
Where the design requires that stainless steel pipe is to be bolted to carbon steel piping, valves
or equipment, then stainless steel bolts, nuts and washers shall be used in conjunction with
insulating sleeves and washers.
8.2.13 Pipe Support – General
The Contractor shall fabricate and install all pipe supports, anchors, guides and other support
attachments in accordance with the details on the drawings, applicable standards,
manufacturer’s recommendations and this specification, with individual pipe system
requirements detailed in following applicable sections (Section 8.2 – 8.10).
Pipe supports for stainless steel pipe systems shall be of the “insulated” type to eliminate
corrosion issues associated with dissimilar metals that fully support the pipe system and
eliminate undue stresses on joints, piping and other components.
Pipes shall be supported from structural steelwork or structural concrete or pre-cast concrete
blocks as per design drawings or approved by the Principal. Where pipe supports are attached
to building structures, the loadings imposed on the structure shall be approved by the Principal.
Pipe supports shall be welded to structural steel only with prior approval from the Principal, the
support and steelwork galvanising or paintwork shall be prepared and painted in accordance
with Standard Specification 100-SP-ST-0004.
The design, fabrication and installation of all structural pipe supports shall be in accordance with
the applicable provisions of AS 3990, AS 1554, and AS 4041.
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Pipe shoes and sliding pipe support attachments shall be centred over the concrete or steel
support beams before any field welding or bolting is carried out.
Drawings shall define all welding to be done on structural members, either by notes, developed
details or welding symbols with supporting structural checks.
All concrete shall comply with Standard Specification 100-SP-CI-0003 and pipe supports
connected to concrete shall be shimmed and grouted.
All pipe work shall be supported so that the pipe may expand and contract freely. Supports shall
be arranged so that any valve, fitting or equipment can be removed without disturbing the
remainder of the pipe work system.
Expansion and contraction shall be taken up on bends or loops or by approved expansion

joints.
All piping shall be supported in a way that prevents vibration and fretting.
Pipe work shall be correctly anchored so as to secure the position of the pipe with consideration
to spacing of supports, pipe work expansion and contraction.
Pipe work shall not be supported by equipment even on a temporary basis. In the event that
equipment is removed all pipe work shall be self-supporting.
Standard hangers and brackets for mobile and vibrating equipment shall include vibration
isolators as part of their construction.
Vertical pipe runs in excess of 3m shall have suitably designed pipe supports, generally located
in the upper half of the rising pipe.
Temporary supports are permitted to facilitate piping installation and prevent overstressing of
pipe work provided they shall be completely removed upon completion. Attaching temporary
supports to stainless steel, carbon steel or lined pipes by welding is not permitted.
8.2.14 Installation of Valves
Valves shall be installed with stems orientated as indicated on piping drawings and hand wheels
and levers shall be easily accessible for operation from grade or platform.
Valves shall not be installed with their stems projecting into the walkways. All valves located
underground or in trenches shall be provided with valve boxes, extension stems and bollards
shown on drawings and as detailed in Sections 9.6 and 9.7.
Relief valves shall be installed in an upright position and accessible from a platform or grade.
Relief valves discharging hazardous liquids or gases, shall be piped to a safe and
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environmentally acceptable location. When discharge piping is fitted to relief valves, the
pressure drop is to be included in the design criteria for the valves.
Chain wheel operators shall be provided for valves with hand wheels more than 2,050 mm
above the operating level. Chains shall clear operating floors by 900 mm and shall not hang in
access areas.
Spacer rings shall be installed with butterfly and non-return valves installed in HDPE, PVC and
Aquamine pipe systems.
See Appendix 1 for flange tightening details
8.2.15 Piping for Rotating Equipment
Pump and compressor piping shall be installed up to a break point between the nearest pipe
support and the equipment. The remainder of the piping shall be site measured, fabricated and
properly fitted between the equipment nozzle and this break point. It is essential that this is
done accurately in order to avoid any external loadings on the equipment connections.
The flanged spools mating with equipment flanges shall be site fitted for correct alignments to
ensure that no stress or load is placed on the equipment and the spool flange shall then be fully
welded in accordance with the requisite welding procedure.
Piping shall be disconnected from the equipment after installation to demonstrate that no stress
has been transferred from piping to equipment and reinstalled.
The following procedure shall be applied for the alignment of flanges to rotating equipment:
 Install; bolt down on shims and grout rotating equipment level on the foundation.
Driver to equipment alignment to be set within manufacturer’s tolerances at the
supplier’s works and re-checked and aligned as required on site prior to pipe work
connection.
 Align pipe work to equipment flanges to within the Suppliers tolerances and in
accordance with this specification.
 Recheck the coupling alignment during the bolting and tensioning of the pipe flanges
to the equipment flanges. The bolting up and tensioning of the flanges shall not affect
the coupling alignment between the driver and the driven equipment.
8.2.16 General Storage Requirements
All piping components shall be stored in a clean area away from the fabrication and construction
activities and handled such that no damage or mixing of materials occurs. Materials shall be
stored on pallets and not on the ground. End caps shall be kept on all components. Threaded
ends shall be protected by end caps.
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Surfaces of piping components shall be kept free of foreign materials such as grease, paint, oil
and the like.
Hooks shall not be used for lifting. Pipes shall not be rolled off or dropped onto the ground or
dragged over the ground.
Valves shall be stored with spindles in vertical positions and relief valves shall be stored upright
in a clean area.
Flange facings shall be protected from damage. Covers shall be securely fastened to flange
facings during handling, transportation and storage at site.
Standard procedures for preservation, packaging, transport and storage of materials shall be
followed.
Partly installed piping components and spools for compressed air shall be protected at all times
from ingress of moisture or foreign matter, by covering and taping.
8.1.17.1 Stainless Steel Materials
Stainless steel materials shall be stored on non-metallic pallets.
Stainless steel piping and components shall be stored in separate areas away from storage
areas for carbon steel and other materials to avoid direct contact between carbon steel and
stainless steel.
8.2.17 Excavation for Buried Piping
Before commencement of any trenching, the Contractor shall carry out all checks required to
identify location of underground cables and piping, and other equipment. The Contractor shall
also obtain any required digging permits and shall comply with any site procedure prior to and
during excavation work.
Excavation of trenches shall be carried out to suit pipe alignments, grades and levels shown on
the Drawings and shall be programmed to minimise the length of open trenches on the site at
any one time.
The trench width shall be determined with regard to bedding, minimum working space, testing
and protection of installed work components. The minimum trench width and clearances
between services and the trench sides or shoring members shall be as shown on the Drawings.
The trench depth shall be the minimum required to achieve the correct cover on the pipe, as
defined on the Drawings.
Trenches shall be kept free of groundwater until each section of main has been completed and
tested. Groundwater shall not be permitted to enter pipes.
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Trench bottoms and the compacted make-up backfill resulting from over-excavation and rock
excavation shall be trimmed or shaped to provide uniform bearing for the various work
components, including pipe collars and similar irregular parts of work components. Over-
excavation below the grade of the trench bottom shall be backfilled and compacted to a density
equal to that of the original ground.
Where rock is encountered, the trench shall be deepened to allow the placing of 150mm
compacted thickness of gravel bedding material beneath the underside of the pipe. In addition,
extra excavation shall be carried out under couplings or fittings to allow for the additional
thickness at the joint.
Blasting shall only be carried out with written approval of the Principal and shall be carried out
by certified operators in accordance with the requirements of the Principal.
If suitable bearing material is not reached at the depths shown on the Drawings, the Principal
shall direct the action to be taken according to the conditions and no material shall be placed on
the exposed sub-grade without prior approval.
In general, unsuitable material shall be removed for a width of at least one diameter on each
side of the pipe and to a depth as deemed necessary by the Principal. The resulting excavation
shall then be backfilled with approved selected granular material.
Excavated material shall be placed in such a position as to cause the least inconvenience to
vehicular traffic and other construction work. Excess or unsuitable material shall be removed
from work areas, deposited and spread neatly at disposal sites nominated by the Principal.
In the event of water being encountered or when rain is likely, adequate provision shall be made
to ensure that the excavation is kept dry during any concreting or pipe laying processes.
8.2.18 Trench Shoring
Barricades shall be erected around trenches. Barricades shall be lit at night as directed by the
Principal.
Where required, trenches shall be shored in accordance with statutory requirements.
The methods of shoring shall be suitable for the application with regard to depth, groundwater,
soil condition, superimposed loads, duration, and construction.
All supporting arrangements shall be designed and constructed on the basis of engineering
calculations, having regard to the specific conditions.
Unless otherwise specified, or directed by the Principal, all temporary supporting arrangements
shall be removed when no longer required.
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8.2.19 Installing Underground Piping
The pipe shall be placed over the trench on timber bearers spaced at a suitable spacing and
pressure tested after welding and prior to laying, or via an alternative method with prior approval
by the Principal.
Identification tape shall be placed above the services in accordance with AS/NZS 2648.1 and
AS/NZS 4275.0-6 to indicate the existence and type of service line.
Any outstanding protective coatings shall be applied, or if completed, touch up work on welded
or damaged areas shall be carried out.
Care shall be exercised to ensure that dissimilar metals are not placed in contact in any part of
the underground pipe systems.
The protective coating shall again be checked for faults and all damaged sections made good.
Piping shall be lowered into the trench, by means of pipe slings.
8.2.20 Buried Pipe Work Protective Coatings
Galvanised pipe work shall not be laid underground unless otherwise specified. Where high
pressure steel lines need to be buried they shall be surface treated with the Denso Petrolatum
system. This comprises a primer, mastic, 55 % overlapped Denso tape, and 55 % overlapped
MP/HD tape. The system shall extend 500mm above the natural ground level.
All remedial welding, field welding and pipe joints shall not be coated until after hydrostatic
testing is completed.
Remedial welding, pipe joints and all other damaged areas of the coating system shall be
repaired in accordance with system manufacturer recommendations.
8.2.21 Trench Backfilling
A "HOLD" point is to be placed on backfilling of trenches until the Principal has inspected the
trench and deemed it satisfactory. Final backfilling of pipe trenches shall not be carried out until
their “As Built” information is surveyed (X, Y, Z co-ordinates accurate to <50mm) and the
installation approved by the Principal.
Trenches shall be backfilled as soon as practicable after testing in accordance with this
specification has been satisfactorily completed and approval has been obtained from the
Principal.
Select Fill material shall be used where specified on the Drawings or as directed by the
Principal
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Material for initial backfilling shall be as shown on the Drawings. At the road formations, the
material shall consist of approved road formation materials.
Initially, the material shall be placed and compacted by suitable hand held plate compactors to a
depth of 300mm above the pipe. The remainder of the backfill and compaction operations may
be carried out by mechanical means provided that no damage or displacement to the pipe can
occur.
At road crossings, the backfill shall be compacted to a density equal to or better than the
adjacent undisturbed road.
The backfill material around service tapping’s and riser fittings shall be sand, unless shown
otherwise on the Drawings.
Sand bedding shall provide continuous support for pipes and fittings and shall be compacted for
the full width of the trench. Backfilling material shall be fine screened and contain no sharp
objects which may damage pipe work or protective coatings.
The material excavated from the trench may, subject to the approval of the Principal, be used
for backfill.
Backfill under roads, crossovers and car parks shall be as shown on Drawings.
The Contractor shall place all valves and flushing point covers and box assemblies as shown on
the Drawings. Valves are to be operable from the final surface level.
Marker Posts shall be provided and installed to the details shown on the Drawings and where
otherwise directed. They shall be used to indicate the position of valves, flushing points, and
other features. Hot dipped galvanised star picket marker posts shall be used.
All in-line and vent valves shall be left fully opened. All flushing points and tappings at
temporary dead ends shall be left shut.
Buried piping shall have a marker tape placed above pipes as shown on the Drawings.
Test records in accordance with AS 4041, or other applicable standards depending on piping
system, shall be kept for each test and shall be forwarded to the Principal upon completion of
each accepted test.

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8.3 Aquamine (Victaulic PVC)
8.3.1 General
Aquamine (Victaulic PVC) spline-type connection piping systems shall be installed in line with
manufacturer’s literature and as designated on design drawings.
All products shall be listed under NSF Standard 14 and certified NSF-PW for use in all potable
water piping systems and shall not be used for compressed air/gas services.
8.3.2 Assembly
Assembly of Aquamine couplings and pipe shall be in accordance with the latest revision of the
Aquamine Assembly and Installation Instructions AM-I-100).
All components (couplings, fittings, valves, gaskets, PVC pipe) shall be of one manufacturer
(Aquamine, LLC or Victaulic Company of America) or approved equivalent.
8.3.3 Pipe supports
All above ground Aquamine piping smaller than DN110 shall be fully supported in cable ladders
All above ground Aquamine piping DN110 and larger shall be supported as specified in
Victaulic’s Aquamine product data and pipe support table for the specific pipe class being
installed.
8.3.4 Aquamine Piping ‐ Installation/Erecting/Construction
Installation of Aquamine piping shall conform to AS 2033 and AS 2566.2 and manufacturers
specifications and data.
All materials shall comply with relevant Australian Standards and manufacturers specifications.
Variations to the materials nominated on the Drawings shall require the approval of the
Principal.
All pipes, valves and fittings shall be carefully examined for cracks, kinks, scoring and other
defects immediately before being installed. Defective equipment shall be rejected.
Where a deviation in the route corresponds to a change in the direction of the pipeline, the pipe
shall be carefully bent in a curve of radius not less than that specified by the manufacturer for
each specific pipe size and rating. Where a deflection exceeds 50°, the pipe shall be cut and a
suitable sweep bend installed opposite the intersection point. The pipe shall then be carefully
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bent each side of the sweep bend in a curve of compliant radius to achieve the final required
deflection.
Above ground Aquamine piping may be placed directly on the ground. If placed on the ground,
all rocks and debris likely to damage the pipe shall be scraped away from an area of 1m either
side of the nominal pipe route in accordance with the Manufacturer’s Instructions.
Piping laid on the ground may move due to thermal expansion and contraction, strong winds,
and flooding. To limit the movement of pipe, pairs of galvanised star pickets or treated pine
posts shall be placed at intervals of not more than 100m, and more frequently where required
around bends, with the inside distance between the pairs of star pickets/posts to be between
100mm and 300mm greater than the outside diameter of the pipe.
For tight bend cases and for pipes larger than DN 200, treated pine posts 100mm diameter, or
larger, shall be used in place of galvanised star pickets.
One picket/post shall be driven either side of the pipe to a depth of 600mm with a double strand
of 2.5mm fencing wire threaded through a hole in each picket/post 100mm above the top of the
pipe and another fencing wire tie located 100mm from the top of the picket/post, with the double
wires tied off and then twisted together to remove any slack in the wire without pulling in the star
pickets/posts.
Pickets shall be capped to prevent injury to personnel.
Aquamine piping shall be laid so that it is capable of operating between the maximum and
minimum service temperatures. There shall be sufficient excess length between anchors to
allow for contraction, and sufficient space allocated for expansion. Adequate allowances shall
ensure that no excessive residual stresses remain in the piping prior to or after start-up of plant
operations for a full pipe case and also during construction or shut down periods for an empty
pipe case in line with manufacturer’s recommendations.
Where excessive expansion is expected, adequate flexibility shall be allowed.
U-bolt guides with two lock nuts shall be loosely clamped (or approved alternative) to allow free
movement of the pipe during expansion and contraction.
Below ground Aquamine piping shall be designed and installed taking into account allowances
for expansion during construction for an empty pipe case while in open trenches to ensure no
damage to piping or connections and for during normal operation when buried.
Aquamine pipe system design and installation shall allow for the following pipe temperature
range cases:
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Table 16: Pipe Temperature Range Cases

Design Case External Pipe Temp.
Minimum (°C) Maximum (°C)
Above Ground Installation – Empty -2º 65º
Above Ground Installation – Operational/Full -2º 50º
Below Ground Installation – Construction -2º 65º
Below Ground Installation – Operational/Full 10º 30º
Note: Refer to the latest Victaulic G-100 general catalogue for additional pressure ratings and
application information.
Snaking of pipes in trenches is only permitted if the final alignment at service temperature is
within 100mm of the correct alignment.
Aquamine pipe is susceptible to absorption of hydrocarbons. Pipe which has been in contact
with hydrocarbons shall not be used. The pipe shall not be installed in contact with soil
contaminated with hydrocarbons.
At the end of the day’s work or at any time when pipe laying is suspended, every open end of
an uncompleted pipeline shall be securely capped with a tight fitting cover. No tools, etc, shall
be allowed to remain in the pipes overnight.
The nominal diameter of each valve shall be the same as the nominal diameter of the pipe in
which the valve is being installed.
Air vent/vacuum breaker valves shall be installed at high points in above ground Aquamine
pipes where there is a possibility of vacuum developing within the pipe.
8.4 Carbon Steel And Stainless Steel Fabricated Piping
8.4.1 General
All carbon steel pipe work and fittings for fire hydrant and hose reel services shall be
galvanised. Painted pipe work shall not be used in these applications. Fire sprinkler system
pipe work and fittings may be un-galvanised, depending on the installation location, as defined
in Standard Engineering Specification Protective Coating Systems 100-SP-ST-0004.
Note: Diesel pipelines between Diesel facilities should be designed to AS 4041 and similar to
pipe work within facilities. This Specification is not intended for AS 2885 design.
Note: This Specification has not been checked to be consistent with AS 2885, rather it is
formed around AS 4041. AS 2885 has different requirements for hydro testing and inspection
and different terminology, e.g. Class 1, 2, 3 for AS4041, and other AS 2885 requirements are:
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1. Location class designation
2. Isolation plan to be approved
3. Hydro testing of ALL joints except final tie in joint.
4. A fracture control plan
5. Calculation of critical defect length
6. Quality control procedures for surface protection including approval
7. Surveillance of the route
For steel pipe work systems, the following pipe sizes (DN, mm) are preferred: 15, 20, 25, 40, 50,
80, 100, 150, 200, 250, 300, 350, 400, 450, 500, 600, 750, 900, 1050 and 1200 to be supplied
in stock length.
8.4.2 Connection to Pipe Systems and Equipment of Dissimilar Metals
Connection of stainless steel piping to other piping systems and equipment, such as tanks and
pumps, of dissimilar metals that may induce galvanic corrosion shall be via an insulated
connection as specified in the data sheets in Section 10.1.
8.4.3 Pipe Fittings
Buttwelded, flanged and threaded fittings shall be in accordance with ANSI/ASME B 16.9, B
16.5, B 16.25, AS 1579 and AS 4087 respectively.
8.4.4 Preparation for Welding – General Requirements
Welding shall be in accordance with AS 4041 or ANSI/ASME B31.3, unless AS2885 applies
(e.g. Diesel Pipelines - C5, C5A, and C5B).
Cutting of pipe may be done either by mechanical means or by flame cutting, depending on the
type of material to be cut. For carbon steel, flame (or arc) cutting and bevelling is acceptable
only if the cut is reasonably smooth and true and all oxides are removed from the flame cut
surfaces by grinding. After flame cutting the bevel end, preparation shall be ground back to
bright and sound metal.
All welding areas shall be adequately protected against inclement weather conditions such as
rain, wind, dust and the like.
All weld end preparations and adjacent areas 50 mm either side of the weld shall be thoroughly
cleaned and degreased prior to welding.
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Welding procedures and qualification tests shall be submitted to the Principal for approval.
Use of permanent backing rings is prohibited. Consumable inserts shall not be used.
End preparation for butt welding shall be in accordance with AS 4041 or ANSI/ASME B16.25.
Defective or damaged weld ends (bevels) shall be examined and repaired. Use of hot or cold
hammering as a means for repair is prohibited.
8.4.5 Welding – General Requirements
All welding operators shall be certified and qualified under the requirements of AS 4041.
Filler materials shall comply with AS 4041.
Welding electrodes shall be stored according to the manufacturer's recommendations.

Electrodes that become damp shall not be dried and used, and shall be discarded.
Weld reinforcement on capping runs shall not exceed the requirements of AS 4041.
Pipe ends shall be cut and prepared for welding in accordance with AS 4041.
Weld sizes shall comply with the qualified weld procedures approved by the Principal for each
type of weld.
Where lined pipe is used the Contractor shall make good the lining on completion of welding.
Prior to any work being done, the Contractor shall submit a procedure for repair of pipe lining for
approval by the Principal.
8.4.6 Welder Qualification – General Requirements
Qualification of welder performance shall be in accordance with AS 1796. Prior to

commencement of welding, the weld procedures and welders qualifications shall be submitted
to the Principal for approval.
The Contractor shall on request submit test pieces, either as samples from each welder, or cut
from welded line as done by each welder, fully prepared for testing by a NATA approved testing
authority. The failure of such tests shall be cause for rejection of the works.
The extent of testing and inspection of welds and the necessary associated procedure shall be
as detailed in AS 4041 and as listed in Section 8.12.1.
8.4.7 Slip on Flanges
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Slip on flanges shall be positioned so that the end of the pipe is recessed from the flange, a
distance equal to the lesser of the pipe wall thickness plus 1.5 mm or 8mm. Seal welding for
slip on flange shall be carefully applied in order to avoid refacing the flange.
Pipes for insertion in slip-on flanges shall be cut square, within 0.5 mm.
8.4.8 Socket Weld Pipe Systems
Pipe for insertion in a socket weld joint shall be cut square within 0.5 mm. A minimum gap of
1.6 mm shall be maintained between the end of the pipe and the bottom of the socket.
8.4.9 Branch Connections
For fabricated carbon steel and stainless steel pipe branch connection requirements, refer to
branch connection chart in Section 8.3.10 of this specification. Fabricated branch connections
shall be in accordance with AS 4041 or AS 1579 for as applicable for individual Pipe Class.
Branch reinforcement shall be as required by AS 4041 or AS 1579 as applicable for individual

Pipe Class. Reinforcement material shall be made from the same pipe material as specified by
the relevant piping class and subject to the same specification requirements as the piping to
which it is attached.
All cuts shall be carefully bevelled and accurately matched to form a suitable preparation for
welding and to permit full penetration of welds between the branch and the run pipe at all points
All reinforcement pads for pressure openings, or each segment of built up type reinforcement
pads for pressure openings, shall be provided with 1/4 inch (6 mm) NPT threaded hole for
testing and venting. The vent hole shall be sealed after completion of the pressure test with
grease or silicon sealant to prevent ingress of moisture.
Branch connections, vent nozzles, trunnions and other attachments including reinforcing pads
shall not be welded over or near longitudinal or circumferential welds in the piping. The
minimum distance from a longitudinal or circumferential weld to the next weld shall be 50 mm
measured between the heat affected zones. For reinforcing pads, the minimum distance
measured between the heats affected zones of the weld in the pipe and fillet weld of the pad
shall be 25 mm.
8.4.10 Pipe Branch Connection Tables
Preferred branch connection arrangements are given in the Branch Connection Tables below.
Equal tees and reducing tees are the preferred branch connections.
Branches shall not be located on removable spools and elbows.

Page 51 of 236
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Page 52 of 236
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Table 17: Pipe Branch Connections C1, C3, C5, C5A, C5B, C6, G1, S2
C1, C3, C5, C5A, C5B, C6, G1, S2 BRANCH CONNECTION TABLE
BRANCH NOMINAL SIZE
RUN NOMINAL 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600 DN
SIZE ½ ¾ 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24 NPS
600 24 C C C C S S S S S B B B B B B A
500 20 C C C C S S S S B B B B B B A
450 18 C C C C S S S S B B B B B A
400 16 C C C C S S S B B B B B A
350 14 C C C C S S S B B B B A
300 12 C C C C S S B B B B A
250 10 C C C C S S B B B A
200 8 C C C C S B B B A
150 6 C C C C S B B A
100 4 C C C C B B A
80 3 C C C C B A
50 2 C C B B A A: Equal Tee
40 1½ B B B A B: Reducing Tee
25 1 B B A C: O-let
20 ¾ B A S: Stub-in
15 ½ A All stub-ins to be checked in accordance with
DN NPS AS 4041 and reinforced where found necessary.
Table 18: Pipe Branch Connections C7
C7 BRANCH CONNECTION TABLE

BRANCH NOMINAL SIZE
RUN
NOMINAL
SIZE 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600 750 900 1050 1200 DN
1 NP
½ ¾ 1
½
2 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48
S
600 24 C C C C W W SR SR SR SR SR SR SR SR SR SR SR SR SR SR
500 20 C C C C W W S S S S SR SR SR SR SR SR SR SR SR
450 18 C C C C W W S S S S S S S S S S S S
400 16 C C C C W W S S S S S S S S S S S
NP
DN
S
C: Threadolet
W: Weldolet
S: Stub-in
SR: Stub-in, reinforced

All stub-ins to be checked in accordance with
AS 4041 and reinforced where found necessary.

Page 53 of 236
100-SP-PI-0001_Rev 3
Table 19: Pipe Branch Connections C8

BRANCH NOMINAL SIZE
RUN NOMINAL
15 20 25 40 50 80 100 150 200 250 300 350 DN
SIZE
½ ¾ 1 1½ 2 3 4 6 8 10 12 14 NPS
350 14 C C C C C SR SR B B B B A
300 12 C C C C C SR B B B B A
250 10 C C C C C SR B B B A
200 8 C C C C C B B B A
150 6 C C C C C B B A
100 4 C C C C B B A
80 3 C C C C B A
50 2 C C B B A A: Equal Tee
40 1½ B B B A B: Reducing Tee
25 1 B B A C: Sockolet
20 ¾ B A SR: Stub-in with reinforcement pad (minimum 6mm thickness)
15 ½ A All stub-ins to be checked in accordance with
DN NPS AS 4041 and reinforced where found necessary.
Table 20: C9 Branch Connection Table

NOMINAL NOMINAL BRANCH SIZE
RUN SIZE 15 20 25 40 50 80 100 150 200 DN
½ ¾ 1 1½ 2 3 4 6 8 NPS
200 8 C C C C C C B B A
150 6 C C C C C B B A
100 4 C C C C B B A
80 3 C C B B B A
A: Equal Tee
50 2 C B B B A
B: Reducing Tee or Tee with Reducing Coupling
40 1½ B B B A C: Weldolet
25 1 B B A
20 ¾ B A Table Notes:
15 ½ A 1. Stub-in connections shall NOT be used for this application.
DN NPS

Page 54 of 236
100-SP-PI-0001_Rev 3
8.4.11 Cold Bending
Carbon steel pipe DN 40 and smaller shall be bent only where cold bending is indicated on
design drawings or approved by the Principal. In all other cases, butt weld, socket weld or
screwed elbows shall be used depending on the piping class. Cold bending shall not be done
on stainless steel piping.
Cold bending shall be carried out using pipe bending machines or presses and dies shall be
employed to prevent flattening.
Unless otherwise noted, the centre line radius of bends shall be five (5) nominal pipe diameters.
Butt welds in the arcs of bends or for the addition of pulling legs shall not be permitted. Butt
welds to be a minimum of 1 pipe diameter from any bend in cold bent pipe.
All bends shall be smooth, free from cracks and surface defects, without buckles and they shall
be within tolerance limits allowed by AS 4041.
8.4.12 Mitre Bends
Segmented bends shall be manufactured by butt welding together segments of pipe, shaped to
produce the required bend. Wherever possible, the segments shall be taken from the same
length of pipe.
The change of centreline at butt welds in segmented bends shall not exceed 30º.
The use of mitre bends shall only be permitted for Piping Class C7, if detailed on pipe
arrangement drawings or with prior approval from the Principal.
8.4.13 Preheat and Heat Treatment
Preheat and interpass temperature control and heat treatment shall be to AS 4041.
8.4.14 Pipe Supports for Fabricated and Threaded Piping
The design and installation of structural pipe supports shall comply with the requirements of AS
3990 and AS 4041 and applicable structural standards.
Pipe supports for stainless steel piping shall be of the “insulated” type to eliminate corrosion
issues associated with dissimilar metals.
As per AS 4041, the maximum recommended spacing between supports for steel pipe,
Schedule 40 or greater, carrying a fluid SG of 1.0 is as below:
Page 55 of 236
100-SP-PI-0001_Rev 3
Table 21: Maximum Recommended Support Spacing for Steel Pipe

DN 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600
Span (m) 1.5 2.0 2.4 3.0 3.4 3.9 4.3 5.2 6.0 7.0 8.0 8.4 8.8 9.0 10 12
Note:
 The above figures are given as a guide and shall not be used in place of pipe support
arrangements on Project design drawings.
 This Table shows recommended maximum spacing between pipe supports for
horizontal straight runs of pipe at maximum operating temperature of 400°C.
 These spacing’s do not prevail over calculated spacing’s and do not apply where there
are concentrated loads between supports, such as flanges and valves.
 These spacing’s are based on a fixed-beam support with a bending stress not
exceeding 16 MPa and insulated pipe with the appropriate contents, and the pitch of
the line being such that sag of 2.5 mm between supports is incorporated in the design
 Steel pipe work not covered by the above table, or that is carrying fluids with an SG
greater than 1.0, shall be supported as per AS 4041 on an individual basis.
8.5 Victaulic Carbon Steel Piping – (Std. Weight & Sch. XS)
8.5.1 IPS & AGS Grooved Piping Systems
All products shall be permitted and/or Listed/Approved by the appropriate codes or standards
organizations including but not limited to: ASME (B31.1, 31.3, 31.9), ASTM, ANSI/AWWA (C-
606), FM, IAPMO, International Code Council (IPC, IMC, IFC), NFPA, NSF, UL, ULC, and VdS.
Piping shall be purchased pre-cut and grooved where ever possible to minimise site grooving
and protective coating touch-up.
Grooved couplings shall meet the requirements of ASTM F-1476.
Notes:
 Refer to the latest Victaulic general catalogue for additional pressure ratings and
 Piping, fittings, seals and components shall be suitable for each particular system
service pressure and pipe class – standard weight or schedule XS.
 All Victaulic products described herein are to be installed in accordance with latest
Victaulic published literature.
Page 56 of 236
100-SP-PI-0001_Rev 3
 All grooved components (couplings, fittings, gaskets, bolts, nuts) shall be of one
manufacturer (Victaulic Company of America) or approved alternative.
8.5.2 Pipe/Grooved – Standard Weight & Schedule XS
Carbon Steel, A-53B/A-106B – IPS or AGS rolled or cut grooved-ends as appropriate to pipe
material, wall thickness, pressures, size and method of joining. Pipe ends to be grooved in
accordance with Victaulic current listed standards conforming to ANSI/AWWA C-606.
Note:
 DN80 to DN300 pipe shall be rolled or cut grooved.
 DN350 to DN600 pipe shall be rolled groove only.
 Painted and galvanised pipe ends affected by site groove rolling or cutting shall have
surface treatment in accordance with Section 8.1.12.
 Pipe grooving shall be performed by personnel who have been trained by a Victaulic
factory trained representative who shall provide periodic review of pipe grooving, with
any identified defects to be rectified.
8.5.3 Mechanical Couplings for Joining Carbon Steel Pipe
Couplings shall be cast of ductile iron conforming to ASTM A-395, grade 65-45-15, and ASTM
A-536, Grade 65-45-12
8.4.3.1 Mechanical Couplings
Mechanical couplings shall be Victaulic Style 07 (Zero-Flex) or Style W07 Rigid couplings
unless otherwise specified or approved by the Principal. Victaulic Style 77 or Style W77
couplings shall be used where system flexibility is desired. Noise and vibration reduction at
mechanical equipment connections may be achieved by installing three style 77 or Style W77
flexible couplings near the vibrations source.
8.5.4 Gaskets
Both coupling gaskets and flange gaskets shall be as specified in the relevant piping class data
sheets for individual fluid classes.
8.5.5 Bolted Branch Outlet
Branch reductions on 2" (DN50) through 8" (DN200) header piping shall be made with Victaulic
hole cut products. Style 920 or Style 920N Mechanical-T Outlet with locating collar engaging
Page 57 of 236
100-SP-PI-0001_Rev 3
into a hole or Style 72 outlet coupling for use in joining grooved pipe with a branch connection at
the joint.
Style 72 couplings and Style 920 and 920N hole cut products may be used with either grooved
connection for the branch line or NPT threaded connection to allow transition to a different pipe
class such as S1, Victaulic Pressfit.
8.5.6 Expansion Joints
Expansion and contraction compensation shall be achieved utilizing either Victaulic Style 150
Mover 2"-6" (DN50-DN150) or Style 155 expansion joints 3/4"-24" (DN20-DN600). Select
expansion joint and support method in accordance with design conditions and performance data
published in Victaulic literature
8.5.7 Fittings
Victaulic fittings shall be full flow ductile iron fittings, steel fittings or segmentally welded fittings
with grooves or shoulders designed to accept Victaulic grooved end couplings. Specific style
numbers are listed in the current Victaulic catalogue for IPS or AGS systems.
Fittings shall be cast of ductile iron conforming to ASTM A-395, grade 65-45-15, and ASTM A-
536, Grade 65-45-12, forged steel conforming to ASTM A-234, Grade WPB 0.375" wall (9,53
mm wall), or fabricated from Std, Wt. C.S. pipe conforming to ASTM A-53, Type F, E or S,
Grade B.
8.5.8 Pipe Supports
Pipe supports shall be in accordance with this specification, manufacturer’s literature and
specifications and applicable Australian Standards and regulatory requirements, with the more
stringent requirement taking precedence.
The design and installation of structural pipe supports shall comply with the requirements of AS
3990 and AS 4041.
Pipe work systems shall be constructed, supported and installed so that the piping may expand
and contract freely. Expansion and contraction shall be accommodated in bends, expansion
loops or expansion joints. Pipe work shall not be supported by equipment and the supports
shall be constructed so as to allow the removal of valves or equipment without requiring the
removal of additional pipe work.
Pipes shall only be supported from structural concrete or structural steelwork.
Where pipe supports are attached to building structures, the loadings imposed on the structure
shall be approved by the Company Representative.
Page 58 of 236
100-SP-PI-0001_Rev 3
Supports installed to concrete shall be shimmed and grouted. All concrete work shall conform
to Standard Specification 100-SP-CI-0003.
Where welded to structural steel, the support and steelwork paintwork shall be prepared and
painted in accordance with Standard Specification 100-SP-ST-0004.
As per AS 4041, the maximum recommended spacing between supports for steel pipe,
Schedule 40 or greater, carrying a fluid SG of 1.0 shall conform to the following:
Table 22: Maximum Recommended Support Spacing for Victaulic Jointed Steel Pipe
DN 80 100 150 200 250 300 350 400 450 500 600
Span (m) 3.9 4.3 5.2 6.0 7.0 8.0 8.4 8.8 9.0 10 12
Note:
 The above figures are given as a guide and shall not be used in place of pipe support
arrangements on Project design drawings.
 These spacing’s do not prevail over calculated spacing’s and do not apply where there
are concentrated loads between supports, such as flanges and valves.
 Steel pipe work not covered by the above table, or that is carrying fluids with an SG
greater than 1.0, shall be supported as per AS 4041 on an individual basis.
8.5.9 Assembly
Pipe system installation shall be performed by personnel who have been trained by a Victaulic
factory trained representative who shall provide periodic review of system installation, with any
identified defects to be rectified.
Pipe ends shall be clean and free from indentations, projections and roll marks in the area from
pipe end to groove for proper gasket sealing.
The gasket style and elastomeric material (grade) shall be verified as suitable for the intended
service as specified.
See the latest copy of Victaulic’s Field Assembly and installation instruction pocket handbook (I-
100) or other included installation instruction prior to attempting assembly.

Page 59 of 236
100-SP-PI-0001_Rev 3
8.6 Victaulic Carbon Steel Piping – Fire Service
8.6.1 General
Victaulic carbon steel pipe material systems that are approved for fire service applications shall
be used for above and below ground applications as specified on design drawings in line with
this specification, manufacturer specifications and regulatory requirements.
All fittings used on fire protection systems shall be Victaulic fittings approved for the application
in line with Victaulic catalogue listed items and regulatory requirements and approved for the
application by Underwriter’s Laboratories (UL) and Factory Mutual (FM).
Note:
 Refer to Victaulic general catalogue for a complete listing of Victaulic products which
are Underwriters Laboratory Listed (Canada and USA) and/or Factory Mutual System
Approved for Fire Protection Piping Systems.
 Refer to the latest Victaulic general catalogue for additional pressure ratings and
 All Victaulic products described herein are to be installed in accordance with latest
Victaulic published literature.
 All grooved components (couplings, fittings, gaskets, bolts, nuts) shall be of one
manufacturer (Victaulic Company of America) or approved alternative.
Pipe grooving shall be performed by personnel who have been trained by a Victaulic factory
trained representative who shall provide periodic review of system installation, with any
identified defects to be rectified.
8.6.2 IPS Grooved Piping Systems
Fire protection piping systems, as further detailed below, shall be installed by using Victaulic
mechanical pipe couplings of a bolted or mechanical locking device type, with central cavity
pressure-responsive gaskets, for use on all systems where specified on the design drawings.
All materials and products shall be either Underwriters Laboratories listed (Canada and USA) or
Factory Mutual Approved, and installed in accordance with Australian Standards, other
applicable Standards and manufacturer’s published recommendations. Grooved end product
manufacturer to be ISO-9001 certified.
To assure system integrity and performance, all mechanical couplings, fittings, flanges, grooved
valves and bolted branch outlets shall be furnished by the same manufacturer (Victaulic
Company of America) or approved alternative. All gaskets shall be of the central cavity-
pressure-responsive design.
Page 60 of 236
100-SP-PI-0001_Rev 3
8.6.3 Pipe (Std. Wt.)
Pipe shall be prepared in accordance with the latest published Victaulic specifications,
ANSI/AWWA C-606, UL, FM NEPA or other standards as applicable.
Steel Pipe shall conform to ASTM A-135, A-795 or A-53.
Grooved End Pipe shall be grooved utilizing Victaulic Vic-Easy® roll grooving tools or prepared
in accordance with Victaulic cut grooving specifications.
Hole Cut Pipe shall have a machine cut hole at a predetermined position, on the centreline of
the pipe, of a size to receive the housing locating collar, in accordance with Victaulic
specifications.
8.6.4 Mechanical Couplings, Fittings and Adaptors
All mechanical couplings, fittings and adaptors etc, used on Victaulic fire service pipe systems
shall be of Victaulic’s IPS range as specified in the relevant Pipe Class data sheet.
8.6.5 Pipe Supports
Pipe supports shall be in accordance with this specification, manufacturer’s literature and
specifications and applicable Australian Standards and Regulatory requirements, with the more
stringent requirement taking precedence.
8.6.6 Assembly
Pipe system installation shall be performed by personnel who have been trained by a Victaulic
factory trained representative who shall provide periodic review of system installation, with any
identified defects to be rectified
Pipe ends shall be clean and free from indentations, projections and roll marks in the area from
pipe end to groove for proper gasket sealing.
The gasket style and elastomeric material (grade) shall be verified as suitable for the intended
service as specified.
See the latest copy of the Victaulic Field Assembly and installation instruction pocket handbook
(I-100) and associated publications
Page 61 of 236
100-SP-PI-0001_Rev 3
8.7 Mining Hose
8.7.1 General
Mining hose shall be as specified in Section 10.1.14 for piping Class H1.
Mining hose installations shall ensure a minimum hose bend radius to the manufacturer’s
requirements or 8 x hose diameter, whichever is greater.
Preformed mining hose bends shall not be used as standard hose is preferred, if required they
shall be classed as a special, requiring pre-approval by the Principal.
8.7.2 Pipe Supports
Mining hose shall be installed with pipe supports as detailed on Project design drawings or as
approved by the Principal.
8.7.3 Installation/ Erecting/Construction
Mining hose shall be handled carefully with nylon slings used and properly placed while
handling mining hose in order to support the hose properly ensuring it is not kinked while
handling and erecting. The hose shall not be dragged over sharp or abrasive surfaces and shall
be stored in a cool dry location away from direct sunlight and high temperatures.
8.8 High Pressure Hose
8.8.1 General
High pressure hose for connection of gland seal water to pumps shall be via a hose assembly
with a swaged NPTT male fitting one end and a swaged swivel JIC fitting and mating NPTT
male nipple (BSP if required for connection to pumps) as detailed in Section 10.1.15 for Piping
Class H2.
8.8.2 Installation/ Erecting/Construction
High pressure hose shall be installed in line with manufacturer’s recommendations in relation to
configuration and bend radius.

Page 62 of 236
100-SP-PI-0001_Rev 3
8.9 Polyethylene Piping (HDPE)
8.9.1 General
Polyethylene piping shall be class PE100 and shall be designed and installed in accordance
with AS 4130, AS 2566.1, AS 2566.2, AS 2033 and standards referenced therein.
The complete installation including testing shall comply with the relevant standards, statutory
regulations including Plumbing Code of Australia, and Water Service Licensing Regulations
(2000) where applicable.
For polyethylene pipe work, the following pipe sizes are preferred (DN, outside diameter, mm):
32, 63, 90, 110, 160, 200, 250, 280, 315, 355, 400, 500 and 630.
Polyethylene piping used above ground shall be supplied with a co-extruded white cover that
reduces the solar heating effect.
8.9.2 Equivalent Pipe sizes
Table 23: Equivalent Polyethylene Pipe Sizes

DN Polyethylene Flange Steel Pipe
32 DN25 DN25
40 DN32 DN32
50 DN40 DN40
63 DN50 DN50
90 DN80 DN80
110 DN100 DN100
160 DN150 DN150
200 DN200 DN200
250 DN250 DN250
280 DN250 DN250
315 DN300 DN300 & DN250
355 DN350 DN350 & DN300
400 DN400 DN400 & DN350
450 DN450 DN450 & DN400
500 DN500 DN500 & DN450
630 DN600 DN600

Page 63 of 236
100-SP-PI-0001_Rev 3
8.9.3 Polyethylene Piping Manufacture and Fabrication
Polyethylene pipe fittings shall be moulded unless otherwise noted on the drawings. Fabricated
fittings shall not be used except where noted on the drawings.
Note: Fittings for PN20 polyethylene pipe work may be fabricated fittings if not otherwise
available.
8.9.4 Polyethylene Branch Connection Table
Preferred branch connection arrangements are given in the Branch Connection Table below.
Standard manufacturer’s catalogue equal tees and reducing tees are the preferred branch
connections.
Table 24: Polyethylene Branch Connection Table
POLYETHYLENE BRANCH CONNECTION TABLE

RUN
NOMINAL BRANCH NOMINAL SIZE
SIZE
25 32 50 63 90 110 160 225 280 315 355 400 450 500 630
630 F F F F F C C C C C C C C C A
500 F F F F F C C C C C C C C A
450 F F F F F C C C C C C C A
400 F F F F F C C C C C X A
355 F F F F F C C C C C A
315 F F F F F C C C C A
280 F F F F F C C C A
225 F F D D B B B A
160 D D D B B B A
110 D B B B B A A: Equal Tee
90 D B B B A B: Reducing Tee
63 B B B A C: Equal Tee and Reducer (S)
50 E E A D: Reducing Tee and Reducer (S)
32 B A E: Reducing Tee and Reducing Coupling (Note 1)
25 A F: Stub‐in
X: No connection possible in "Vinidex" catalogue
Notes:
1. Tapping saddles may be used as an alternative for branches up to and including DN50
2. DN25‐50 pipe is site run
3. Do not use sizes; 40, 125 140, 200, 250, 560, 710 O.D.

Page 64 of 236
100-SP-PI-0001_Rev 3
8.9.5 Polyethylene Pipe Welder Qualification
Welding of polyethylene pipes shall be carried out by properly qualified and experienced
operators. The use of unqualified operators will not be accepted. The Contractor shall supply a
list of the accredited welders together with their relevant qualifications and welder accreditation
number.
8.9.6 Polyethylene Pipe Weld Testing
Welding of polyethylene pipes will not be allowed without having an approved “Weld
Procedure”. Approval of “Weld Procedure” shall be based on destructive tensile fracture test.
The test results shall indicate ductile separation mode of the weld zone with failure at a stress
which shall not be less than 0.8 of that of the virgin parent pipe. This test is performed with the
bead removed.
Field welding shall be audited against the approved “Weld Procedure”. Field welding will be
inspected by the Principal to confirm cleanliness, alignment, welding temperature, cycle times
and interface pressure are in accordance with the contractors approved “Weld Procedures”.
Non-conformance will result in the contractor, at his expense, cutting out the weld and re-
welding it in accordance with their approved “Weld Procedure”. Weld beads indicating a poor
join may also form basis of a non-conformance.
The Contractor shall allow for a minimum of six (6) test samples to be cut and sent to an
independent, accredited laboratory where tensile fracture tests are to be conducted in
accordance with ASTM F2634-10. The laboratory is to describe if the specimens are visually
sound and separate in a ductile manner. Brittle separation modes or tests which fail at a stress
of less than 0.8 of that of the virgin parent pipe will be judged as unsatisfactory, resulting in a re-
weld and further investigation. Test results shall be issued directly and solely to the Principal.
Test results may be issued to the contractor at the discretion of the Principal.
Weld traceability shall be maintained throughout the works. Each weld shall have a Weld Sheet
filled out.
Weld Sheets shall report:
 Approved Test Procedure number in use.
 Unique weld number referenced on a Contractor supplied weld map.
 Welder accreditation number.
 Ambient Temperature.
 Confirmation butting pipe or fitting has the same wall thickness.
 Confirmation butt ends are aligned, cleaned and planed.

Page 65 of 236
100-SP-PI-0001_Rev 3
 Butt fusion machine identification number.
 Confirmation butt fusion machine alignment checked and in good condition.
 Confirmation butt fusion machine hot plate checked and in good condition.
 Confirmation butt fusion machine hydraulics, gauges, valves checked and in good
condition.
 Welding Temperature (ie. temperature of hot plate).
 Soak time, or heating time.
 Weld Interface Pressure and time.
 Cooling time clamped.
 Welders signature.
Weld Sheets are to be issued to the Company Representative on a daily basis.
8.9.7 Polyethylene Piping ‐ Installation/Erecting/Construction
Installation of Polyethylene piping shall conform to AS 2033 and AS 2566.2.
All materials shall comply with relevant Australian Standards. Variations to the materials
nominated on the Drawings shall require the approval of the Principal.
Polyethylene pipe connections shall be made using fusion weld fittings (Site), butt weld fittings
or using mechanical joint fittings in accordance with this specification. Outer flange rings shall
be installed when plastic pipe flanges are connected to valves. Spacers shall be used when
wafer type butterfly valves are used to ensure free movement of the disc.
Polyethylene piping shall be laid so that it is capable of operating between the maximum and
minimum service temperatures. There shall be sufficient excess length between anchors to
allow for contraction, and sufficient space allocated for expansion. Adequate allowances shall
ensure that no excessive residual stresses remain in the piping prior to or after start-up of plant
operations. Where excessive expansion is expected, adequate flexibility shall be allowed.
U-bolt guides with two lock nuts shall be loosely clamped (or approved alternative) to allow free
movement of the pipe during expansion and contraction.
All pipes, valves and fittings shall be carefully examined for cracks, kinks, scoring and other
defects immediately before being installed. Defective equipment shall be rejected.
Pipe stored on site in coils shall have protective caps securely fixed to open ends to prevent
entry of any foreign matter. The caps shall remain in position until ready for jointing.
Page 66 of 236
100-SP-PI-0001_Rev 3
Where a deviation in the route corresponds to a change in the direction of the pipeline, the pipe
shall be carefully bent in a curve of radius not less than 22 times the DN size of the pipe.
Where a deflection exceeds 50°, the pipe shall be cut and a suitable sweep bend installed
opposite the intersection point. The pipe shall then be carefully bent each side of the sweep
bend in a curve of radius as specified above, to achieve the final required deflection.
Above ground polyethylene piping may be placed directly on the ground. If placed on the
ground, all rocks and debris likely to damage the pipe shall be scraped away from an area of
1m either side of the nominal pipe route in accordance with the Manufacturer’s Instructions.
Piping laid on the ground may move due to thermal expansion and contraction, strong winds,
and flooding. To limit the movement of pipe, pairs of galvanised star pickets or treated pine
posts shall be placed at intervals of not more than 100m, and more frequently where required
around bends, with the inside distance between the pairs of star pickets/posts to be between
100mm and 300mm greater than the outside diameter of the pipe.
For tight bend cases and for pipes larger than DN 200, treated pine posts 100mm diameter, or
larger, shall be used in place of galvanised star pickets.
One picket/post shall be driven either side of the pipe to a depth of 600mm with a double strand
of 2.5mm fencing wire threaded through a hole in each picket/post 100mm above the top of the
pipe and another fencing wire tie located 100mm from the top of the picket/post, with the double
wires tied off and then twisted together to remove any slack in the wire without pulling in the star
pickets/posts.
Pickets shall be capped to prevent injury to personnel.
Above ground polyethylene piping shall be installed with allowance for expansion and
contraction due to temperature variation for an empty pipe case, such as during construction or
shut down periods, and for a full pipe case such as during normal operation, in line with
manufacturer data and recommendations.
Below ground polyethylene piping shall be designed and installed taking into account
allowances for expansion during construction for an empty pipe case while in open trenches to
ensure no damage to piping or connections and for during normal operation when buried.
Polyethylene pipe design and installation shall allow for the following pipe temperature range
cases:
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Table 25: Pipe Temperature Range Cases

Design Case External Pipe Temp.
Minimum (oC) Maximum (oC)
Above Ground Installation – Empty
White co-extruded coating -2º 50º
Above Ground Installation – Operational/Full
White co-extruded coating 10º 35º
Below Ground Installation – Construction -2º 65º
Below Ground Installation – Operational/Full 10º 30º
Snaking of pipes in trenches is only permitted if the final alignment at service temperature is
within 100mm of the correct alignment.
PE pipe is susceptible to absorption of hydrocarbons. Pipe which has been in contact with
hydrocarbons shall not be used. The pipe shall not be installed in contact with soil
contaminated with hydrocarbons.
At the end of the day’s work or at any time when pipe laying is suspended, every open end of
an uncompleted pipeline shall be securely capped with a tight fitting cover. No tools, etc, shall
be allowed to remain in the pipes overnight.
Care shall be taken to brush clean the inside of valves and fittings immediately prior to
installation. The pipe ends shall likewise be carefully brushed clean before jointing.
In the case of fusion jointing techniques, the pipe ends shall be prepared in strict accordance
with the Manufacturer’s Specification.
The nominal diameter of each valve shall be the same as the nominal diameter of the pipe in
which the valve is being installed.
Air vent/vacuum breaker valves shall be installed at high points in above ground polyethylene
water pipes where there is a possibility of vacuum developing within the pipe.
8.9.8 Pipe Supports for Polyethylene Piping
Above ground polyethylene piping smaller than DN110 shall be continuously supported and
secured against uplift, standard electrical cable ladder sections shall be used. Ladders shall be
fixed using cyclone clips or approved alternatives.
Pipes within cable ladders shall be fixed as follows:
 With sliding U bolts, saddles or similar at changes of direction to prevent excessive

movement while still allowing movement as required by expansion and contraction;
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At 25 metre maximum intervals along straight runs to prevent uplift by cyclonic winds while
facilitating pipe work expansion and contraction.
For HDPE piping with an above ground installation temperature rating of 50ºC and operational
temperature of 30ºC carrying a fluid with an SG of 1.0, spans between supports shall not
exceed that listed below:
Table 26: Maximum Support Spacing for HDPE Pipe

DN 32 63 90 110 160 200 250 280 315 355 400 500 630
PN6.3, SDR 26 Cable ladder 1.35 1.70 1.96 2.26 2.44 2.65 2.87 3.09 3.61 4.22
Span(m)
Span(m)
Span(m)
PN12.5, SDR 13.6 Cable ladder 1.57 2.00 2.35 2.70 2.91 3.18 3.44 3.70 4.31 5.05
Span(m)
PN16, SDR 11 Cable ladder 1.65 2.13 2.48 2.87 3.09 3.35 3.61 3.92 4.52 4.52
Span(m)
Span(m)
Note:
 Supports shall be provided either side of flanged connections on pipe lines larger than
DN160.
 Valves and other heavy pipe line components shall be supported independently to the
pipe system
 Pipe supports shall provide means for accommodation of pipe thermal expansion and
contraction
Where the fluid is of SG greater than 1.0, the span shall be reduced in accordance with the
following formula:
Pipe Support Span = Pipe Support Span (for fluid of SG=1.0)
Fluid SG
Pipes shall only be supported from structural concrete or structural steelwork.

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8.10 Rubber Lined Carbon Steel Piping
8.10.1 General
The rubber lining materials and methods of application shall be as detailed in this specification
and to manufacturers requirements.
Make up pieces shall be site measured, fabricated, lined and then erected at site ensuring that
no external loadings are exerted on the equipment or mating flanges.
Flanged spools shall be fabricated and lined in accordance with the relevant Codes and
Supplier’s recommendations. The rubber lining shall be turned out onto the flange up to the ID
of the bolt holes or 50mm, whichever is the shorter. Another piece of the same material and
thickness shall be used to cover the remainder of the flange face. Bends and elbows shall have
flanged ends.
Piping Class R3, Victaulic rubber lined pipe system; rubber lining details and end finishing shall
be to the Victaulic standard specification as listed in the Pipe Class R3 data sheet in Section
10.1.30 for abrasion resistance service.
8.10.2 Specification of rubber
The rubber lining material for each specific application shall meet the following applicable
specifications:
 Cured hardness: 40 to 45 Shore A hardness (to AS 1683.15.2) for Slurry.
 60 Shore A hardness (to AS 1683.15.2) for Chutes.
 Tensile strength: minimum 13.8MPa up to 20.7MPa.
 Elongation: minimum 700%.
 Average total lining thickness shall be as specified in the Data Sheet.
8.10.3 Surface Preparation for Rubber Lining
All metal surfaces to be rubber lined shall be abrasive blasted to AS 1627.4 Class 2½ with the
method used to be open dry blasting and abrasives shall be new and unused and contain less
that 30-PPM of sodium chloride.
Silica sand shall not be used for abrasive blasting.

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Abrasive blasting shall not be carried out when the relative humidity exceeds 85% or when the
ambient temperature is less than 3ºC above dew point. These conditions shall be monitored and
recorded throughout the blasting operation.
The abrasive blasting shall produce a surface profile in the range of 40-75µm and shall be
confirmed using the comparator method specified in AS 1627.4.
On completion of abrasive blasting the surfaces shall be blown down with clean dry compressed
air or vacuum cleaner to remove dust particles, residual abrasive and debris.
The primer shall be applied within four hours of completion of abrasive blasting and before any
visible surface discoloration occurs.
Surface preparation for painting of rubber lined pipes and fittings shall be carried out
concurrently. However, final paint coatings shall be applied after the completion of rubber lining
to prevent damage during the lining application.
8.10.4 Rubber Application
Rubber lining shall not be carried out when:
 Relative humidity is above 85%.
 Ambient temperature is less than 3ºC above dew point.
 When metal or rubber temperature is above or below the recommended values of the
primer/adhesive manufacturers.
The rubber sheets shall be completely bonded to the metal surface without tensioning or
bridging. All edges and seams shall be laid straight. Joints and seams shall be staggered to
avoid more than 2 thicknesses of rubber at any point. The order of preference for type of joints
shall be:
 Overlap scarf joints.
 Straight scarf joints (for chemical resistant lined pipe, scarf shall be 35mm).
 Strapped joint.
 Butt joint with approved filler/sealant (e.g., polyurethane).
Overlapping edges shall be skived and turned down to give a smooth appearance with the
exposed edge of the upper lap facing downstream of the flow direction indicated on (or obvious
from) the drawings.
All lined flange faces shall be buffed smooth to ensure sealing.

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The lining shall cover the entire surface area of vessels specified on drawings and lap over the
edges to assist shedding of liquid.
Special attention shall be paid to the selection of the most suitable rubber and methods of
rubber lining at locations where the applied lining is stressed, (e.g., on open ended pipes and
tank lips where the rubber has to be wrapped around the edge). Approval shall be obtained
from the Principal with regard to proposed materials and methods for such cases.
8.10.5 Repair of Lining
The Contractor shall obtain approval from the Principal prior to the repair of localized defects,
pinholes, blisters or unbonded areas. Repairs shall be done by cutting the affected areas back
to the base metal and patching with the original lining material. Covering patches shall be
circular wherever possible and shall overlap sound material by at least four times the lining
thickness. Such overlaps however, shall not exceed 32 mm.
8.10.6 Rubber Lined Spool and Component Identification
All rubber lined pipes and fittings shall be identified as specified by their design in conjunction
with the following information contained on a clearly marked identification label attached to each
item:
 Manufacturer
 Type
 Chemical/Industry name
 Date of manufacture
 Permissible storage conditions
 Temperature ºC Min/Max
 RH % Min/Max
 Shelf life at storage conditions
 Flow direction (if applicable)
8.10.7 External Protective Coating
The external protective coating of rubber lined carbon steel pipes shall be in accordance with
Section 8.1.12 of this specification.

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8.10.8 Storage and Handling of Lined Steel Pipes
Storage and handling of lined steel pipes shall be as follows:
 All pipes and piping components shall be stored strictly in accordance with
manufacturer’s recommendations.
 Pipes and piping components shall be handled and stored in such a way that the lining
and other materials are not damaged.
 All rubber lined items shall be protected against possible mechanical damage during
transport, storage and handling.
 Lined surfaces subject to exposure to sunlight during transport and storage prior to
installation shall be protected by a suitable coating or similar as specified by the
manufacturer.
 All materials which have been stored for longer than the specified shelf life or exposed
to conditions outside the permissible storage conditions shall be discarded and
replaced.
8.10.9 Rubber Lined Pipe Inspection and Testing
8.9.9.1 General
Each pipe spool shall be Hydro Tested to the pressure specified for the pipe class prior to
rubber lining and then have full Continuity (Spark) Testing carried out prior to deliver to site
and/or installation.
Full and traceable records shall be maintained for fabrication and testing of each pipe spool.
8.9.9.2 Quality Assurance and Traceability
ITP’s and other quality control procedures and documents to be used during rubber lining shall
be approved by the Principal prior to commencement of the job.
Records of all test reports for each piece of lined equipment shall be submitted to the Principal
according to the schedule given in the Contract Documents.
8.9.9.3 Inspection
Each work piece, whether shop or site lined shall be subject to inspection and acceptance by
the Principal.
The Principal shall have access to all stages of the rubber lining material supply and application.
When there is a large quantity of a particular group of items to be lined, an initial trial batch shall
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be subject to an over inspection and test procedure. Results of the above trial batch shall be
used to modify the ITP before proceeding with the balance of items.
Inspection points shall be established as follows:
 Prior to surface preparation.
 Immediately after surface preparation.
 Immediately after application of adhesive.
 Immediately after lining application.
 After curing of rubber (for uncured lining).
 During spark testing.
 Final inspection prior to dispatch or handover.
All defects found during the above inspections shall be repaired and re-inspected. If more than
5 defects are detected within a 10 square meter area, the entire section shall be stripped and
relined according to the original procedure.
8.9.9.4 Testing
Inspection and testing of all lined items shall be carried out in accordance with BS 6374, Part 5:
1985, Section 5, and AS 1683.
Testing shall include, but not be limited to:
 Monitoring of ambient conditions during entire lining operation.
 Lining thickness test.
 Hardness test (AS 1683, Part 15.2).
 Adhesion tests using sample plates to be carried out according to AS 1683, Part 14.1
and 14.2. Adhesion strengths shall comply with values specified in Table 2 of BS
6374, Part 5. Values used shall be adjusted for service temperature according to
continuity of lining test (spark test).
No rubber-lined item shall be commissioned without the completion of tests specified above and
on the ITP’s.
8.9.9.5 Continuity (Spark) Testing
Continuity testing of lined items shall be carried out using high frequency AC equipment in
accordance with BS 6374, Part 5, Section 6.1 and Appendix B. The spark testing shall cover
the entire lining area of all rubber-lined items including pipe and fittings with special attention to
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scarfed joints. Spark testing shall be witnessed by the Principal and shall form a 'hold' point in
the ITP.
Due to the variable nature of spark produced by a given machine under different conditions,
details of testing such as:
 Calibration intervals,
 Spark length,
 Maximum recommended voltages for rubbers tested,
 Electrode shape shall be indicated in the Method Statement and approved by the
Principal prior to commencement of continuity testing.
The following features or alternatives approved by the Principal shall be used to achieve
satisfactory and consistent results in continuity testing:
 Two separate calibration settings using sample calibration plates with similar lining for
skive/overlap joints and plain lining.
 Spark length to be set 2-3 mm longer than the joint length or lining thickness.
 Electrode shapes to suit the contour of lining being tested (e.g., L shaped or flat brush
for large flat areas, curved brush of suitable radius for pipe lining, short straight point
for small areas of complex contour).
8.10.10 Pipe supports
Rubber lined piping shall be installed with pipe supports in line with Project design drawings and
as specified in Section 8.3.14.
8.10.11 Rubber Lined Piping ‐ Installation/Erecting/Construction
Flanged spools shall be transported to work site and erected in accordance with the Supplier’s
recommendations and relevant codes.
Repairs to damaged lining shall be done by cutting the affected area to the base metal and
relining the affected area in accordance with the procedure employed for the original lining as
per the manufacturer. Repair procedure shall be a hold point on the ITP and shall be submitted
to the Principal for approval prior to commencing work.
Welding, cutting or other hot processes shall not be carried out on or in the vicinity of rubber
lined items.

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8.11 Polyurethane Lined Carbon Steel Piping
8.11.1 General
The polyurethane lining materials and methods of application shall be as detailed in this
specification and to manufacturers requirements.
Make up pieces shall be site measured, fabricated, lined and then erected at site ensuring that
no external loadings are exerted on the equipment or mating flanges.
Flanged spools shall be fabricated and lined in accordance with the relevant Codes and
Supplier’s recommendations.
The impingement angle of the fluid in the pipe shall not be greater than 60 degrees.
The fluid in the pipe shall have a PH in the range of 1.5 – 13.
Organic fluids (e.g. kerosene, toluene) shall not be used on Polyurethane.
Corrosion allowance for external corrosion 15% of wall thickness.
ANSI CL 150# and ANSI CL 300# flanges should be used.
Piping Class U1, Polyurethane lined pipe system; polyurethane lining details and end finishing
shall be to the standard specification as listed in the Pipe Class U1 data sheet in Section
10.1.31.
8.11.2 Specification of Polyurethane
The polyurethane lining material for each specific application shall meet the following applicable
specifications:
 88 Shore A hardness
 Tensile strength: minimum 31MPa.
 Elongation: 450%
 Average total lining thicknesses:
• DN150 – 8mm
• DN200 – 10mm
• DN250 to DN400 – 12mm
• DN450 and above – 16mm

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8.11.3 Polyurethane Branched Connection Table
Preferred branch connection arrangements are given in the Branch Connection Table below.
Standard manufacturer’s catalogue equal tees and reducing tees are the preferred branch
connections.
Table 27: U1 Branch Connection Table
U1 BRANCH CONNECTION TABLE

Nominal Run
15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 600 750 DN
Size
0.5 0.75 1 1.5 2 3 4 6 8 10 12 14 16 18 20 24 30 NPS
750 30 S S S S S B B B B B B B A
600 24 S S S S S B B B B B B A
500 20 S S S S B B B B B B A
450 18 S S S S B B B B B A
400 16 S S S B B B B B A
350 14 S S S B B B B A
300 12 S S S B B B A
250 10 S S B B B A
200 8 S S B B A
150 6 S B B A
100 4 B B A
A: Equal Tee
80 3 B A B: Reducing Tee
S: Stub‐in
50 2 A
40 1.5
25 1
20 0.75
15 0.5 Remarks:
1. All stub‐in connections shall be checked in accordance with the pressure design requirements of AS4041 and
DN NPS reinforcements shall be provided where found necessary

8.11.4 Surface Preparation for Polyurethane Lining
All metal surfaces to be polyurethane lined shall be abrasive blasted to AS 1627.4 Class 2½
with the method used to be open dry blasting and abrasives shall be new and unused and
contain less that 30-PPM of sodium chloride.
Silica sand shall not be used for abrasive blasting.

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Abrasive blasting shall not be carried out when the relative humidity exceeds 85% or when the
ambient temperature is less than 3ºC above dew point. These conditions shall be monitored and
recorded throughout the blasting operation.
The abrasive blasting shall produce a surface profile in the range of 40-75µm and shall be
confirmed using the comparator method specified in AS 1627.4.
The blasted surface shall be inspected for removal of grease, oils and rust. Freshly blasted
surfaces may be washed down with MEK (Methyl Ethyl Ketone).
Within 2 hours of blasting the primer and bonding agent must be applied.
Surface preparation for painting of rubber lined pipes and fittings shall be carried out
concurrently. However, final paint coatings shall be applied after the completion of rubber lining
to prevent damage during the lining application.
8.11.5 Polyurethane Application
Polyurethane lining shall not be carried out when:
 Relative humidity is above 85%.
 Ambient temperature is less than 3ºC above dew point.
 Abrasive blast metal surfaces to remove grease, oils and rust as above.
 Wash down metal surfaces with MEK.
 Apply one coat of chemloc 219 barrier coat applied and within 48 hours apply a coat of
chemloc 213.
 Preheat metal part to 105°C before casting.
 Cast mixture of polyurethane prepolymer and crosslinking agent and cure according to
manufacturers procedures.
8.11.6 Polyurethane Lined Spool and Component Identification
All polyurethane lined pipes and fittings shall be identified as specified by their design in
conjunction with the following information contained on a clearly marked identification label
attached to each item:
 Manufacturer
 Type
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 Chemical/Industry name
 Date of manufacture
 Permissible storage conditions
 Temperature ºC Min/Max
 RH % Min/Max
 Shelf life at storage conditions
 Flow direction (if applicable)
8.11.7 External Protective Coating
The external protective coating of polyurethane lined carbon steel pipes shall be in accordance
with Section 8.1.12 of this specification.
8.11.8 Storage and Handling of Lined Steel Pipes
Storage and handling of lined steel pipes shall be as follows:
 All pipes and piping components shall be stored strictly in accordance with
manufacturer’s recommendations.
 Pipes and piping components shall be handled and stored in such a way that the lining
and other materials are not damaged.
 All rubber lined items shall be protected against possible mechanical damage during
transport, storage and handling.
 Lined surfaces subject to exposure to sunlight during transport and storage prior to
installation shall be protected by a suitable coating or similar as specified by the
manufacturer.
 All materials which have been stored for longer than the specified shelf life or exposed
to conditions outside the permissible storage conditions shall be discarded and
replaced.
8.11.9 Polyurethane Lined Pipe Inspection and Testing
In service inspection can be made by visual means and thickness can be tested using a
ultrasonic gauge.
Polyurethane linings shall be spark tested at 20 kva on all acidic slurry lines to ensure the
integrity of the lining.
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8.12 Victaulic Pressfit 316 Stainless Steel Piping
8.12.1 General
The Vic-Press 316 stainless steel system, ½" – 2" (DN15-DN50) schedule 5S, shall contain
Victaulic stainless steel Pressfit fittings, couplings and Vic-Press 316 certified pipe. Vic-Press
316 couplings, fittings, and approved pipe shall be UL/ULC classified to ANSI/NSF 61 for cold
+86 degrees F (+30 degrees C) and hot +180 degrees F (+82 degrees C) potable water service.
This system shall be valid to a maximum working pressure of 300 psi (2065 kPa) for water, oil,
gas, chemical, air and vacuum services.
Notes:
 All components shall be from the one manufacturer, Victaulic Pressfit, or approved
equivalent.
 Refer to the latest Victaulic G-100 general catalogue for additional pressure ratings
and application information.
 All Victaulic Pressfit pipe work shall be installed in accordance with latest Victaulic
published literature.
 Particular attention shall be given to ensuring that all compressed air pipe work slopes
towards automatic drain points.
8.12.2 Pipe
Pipe shall be Vic-Press 316 stainless steel pipe, 0.065 wall, (1,65mm wall) ASTM A-312 grade
316/316L and be Certified for use with Pressfit products. Pipe shall be full finished annealed
with polished O.D.
8.12.3 Couplings, Fittings
Coupling and fitting housings shall be Pressfit products formed of approved 316/316L stainless
steel tubing with self-contained O-ring seals in the coupling/fitting ends.
Transition connection to or from another piping class shall be via Style 580 NPT male or female
threaded adaptors.
8.12.4 Connection to Pipe Systems and Equipment of Dissimilar Metals
Connection of Piping Class S1 stainless steel to other piping systems and equipment, such as
tanks and pumps, of dissimilar metals that may induce galvanic corrosion shall be via an
insulated connection as specified in the S1 Piping Class data sheet in Section 10.1.32.
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8.12.5 Pipe Preparation
Schedule 5 steel pipe shall be square cut plus or minus 0.030" (0,76 mm), properly deburred
and cleaned to ensure leak-tight O-ring seal.
8.12.6 Assembly
Pipe ends must be marked at the required location and fully inserted into the coupling/fitting
housing up to the pipe stop (except for Style 508 Slip Coupling which does not contain internal
pipe stops). All instructions as found in the Victaulic “Pressfit Product Assembly Instructions”, I-
500 shall be followed. Fitting ends shall be pressed onto the pipe using only a Victaulic Pressfit
Tool equipped with the proper size pressing jaws in accordance with the latest Victaulic Tool
operating and maintenance instruction manual.
8.12.7 Pipe Supports
Pipe supports shall be of the “insulated” type to eliminate corrosion issues associated with
dissimilar metals that fully support the pipe system and eliminate undue stresses on joints,
piping and other components.
Additionally, the method of support shall be such as to allow movement of the pipes where
required and to provide drainage, etc., as may be specified by the designer.
The maximum hanger spacing corresponds for Pressfit piping shall be to ASME B31.1, B31.3 or
B31.9 as noted below.
Table sourced from Victaulic literature – confirm latest data at time of installation.
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8.13 Pipe Work Commissioning And Testing
An inspection and Test Plan (ITP) shall be submitted for written approval by the Principal prior
to work being undertaken.
Inspection and testing shall be carried out before any painting or coating is applied.
Inspection shall include visual examination and any other additional examination necessary to
ensure compliance with this specification. NDE and pressure test records shall be submitted to
the Principal for approval.
8.13.1 Visual Inspection and NDE Requirements
The extent of testing and inspection of pipe systems and welds shall be as required by the
applicable system design standard, this specification and as specified in the following table
unless otherwise approved by the Principal.
Meaning of Abbreviations:
RT = Radiographic Testing
UT = Ultrasonic Testing
MPT = Magnetic Particle Testing
LPT = Liquid Penetrant Testing

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Table 28: Piping Class NDE Requirements
Piping Class NDE Requirements

Class Fluid Max. Service AS 4041 Visual NDE NDE Requirements
Pressure Pipe Class Requirements % % Examination
Examination
A1 PO, RW, PW, SW As Listed N/A 100% - Note 3 N/A
C1 PW, GW, PA, IA, 1,600 kPa 3 100% - Note 1 & 2 N/A (Note 4)
OW, WW, CW
C2 PW, GW, OW, WW 1,600 kPa 3 100% - Note 1 & 2 N/A (Note 4)
C3 SL, TL 2,400 kPa 3 100% - Note 1 & 2 Shop fab: 5% RT
Field fab: 10% RT
(Note 4)
C4 SL, TL 2,400 kPa 3 100% - Note 1 & 2 N/A (Note 4)
C5 DO, (EO), (GO), 1,000 kPa 3 100% - Note 1 & 2 Shop fab: 10% RT
(TO), (GRL), (WO), Field fab: 10% RT
HO.
(Note 4)
C5A DO 1,200 kPa 3 100% - Note 1 & 2 Shop fab: 10% RT
Field fab: 10% RT
(Note 4)
C5B DO 4,000 kPa 3 100% - Note 1 & 2 Shop fab: 10% RT
Field fab: 10% RT
(Note 4)
C6 SL, TL 1,600 kPa 3 100% - Note 1 & 2 N/A (Note 4)
C7 PW 1,000 kPa 3 100% - Note 1 & 2 N/A (Note 4)
C8 TL 7,500 kPa 3 100% Note 1&2 Shop fab: 5% RT
Field fab: 10% RT
Note (4)
C9 EO, HO, GO, 1600kPa 3 100% - Note 1 & 2 Shop fab: 10% RT
TO,GRL,WO Field fab: 10% RT
(Note 4)
D1 PO, RW 1,000 kPa 3 100% - Note 1 & 2 N/A
G1 PW, GW, PA, IA, 1,600 kPa 3 100% - Note 1 & 2 N/A (Note 4)
FW, OW, WW
G2 PW, GW, FW, OW, 1,600 kPa 3 100% - Note 1 & 2 N/A (Note 4)
WW
H1 SL, TL, PW 700 kPa N/A Manufacturers’ Std. N/A
H2 GW 3,000 kPa N/A Manufacturers’ Std. N/A
H3 IA, PA, PW, RW 2,000 kPa N/A Manufacturers’ Std. N/A
P1 PO, RW, PW, FL, 500 kPa N/A 100% - Note 3 N/A
SW, OW, WW
P2 PO, RW, PW, SW, 550 kPa N/A 100% - Note 3 N/A
OW, WW, SL
P3 PO, RW, PW, FL, 640 kPA N/A 100% - Note 3 N/A
SW, OW, WW
P4 PO, RW, PW, SW, 700 kPa N/A 100% - Note 3 N/A
OW, WW
P5 PO, RW, PW, GW, 800 kPa N/A 100% - Note 3 N/A
FL, SW, OW, WW
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Piping Class NDE Requirements

P6 PO, RW, PW, GW, 870 kPa N/A 100% - Note 3 N/A
SW, OW, WW
P7 PO, RW, PW, GW, 1,000 kPa N/A 100% - Note 3 N/A
SL, TL, SW, OW,
WW
SL, TL, SW, OW,
WW
SL, TL, SW, OW,
WW, CW
SL, TL, FW, SW,
OW, WW
P11 PO, RW, PW, SL, 1,600 kPa N/A 100% - Note 3 N/A
TL, SW, OW, WW
P12 PO,RW,PW,SL,SW 1600 kPa N/A 100% - Note 3 N/A
,OW,WW
R1 SL, TL 700 kPa 3 100% - Note 1 & 2 Shop fab: 0% RT
Field fab: 0% RT
100% spark test
(Note 4)
R2 SL, TL 2,400 kPa 3 100% - Note 1 & 2 Shop fab: 5% RT
Field fab: 10% RT
100% spark test
(Note 4)
R3 SL, TL 700 kPa 3 100% - Note 1 & 2 Shop fab: 0% RT
Field fab: 0% RT
100% spark test
(Note 4)
S1 PO, PA, IA 1,600 kPa 3 100% - Note 1 & 2 N/A
S2 PO, RW 1,600 kPa 3 100% - Note 1 & 2 N/A (Note 4)
W1 SW, OW, WW, SE As Listed N/A 100% - Note 3 N/A
W2 SE, WW Atmos. N/A 100% - Note 3 N/A
Notes:
1. Visual examination shall be performed prior to any other Non-Destructive Examination or

pressure testing.
2. Visual examination of all pipe systems and welds fabricated to AS 4041 and AS 1579 shall
conform to the requirements of AS4037 (Pressure Equipment – Examination and Testing),
Section 3.2 and table 8.4.
3. Visual examination of all pipe systems components and joints shall be taken across the full
extent of individual pipe systems to ensure system quality and integrity in conjunction with
applicable design/installation standard requirements.
4. NDE shall be performed in accordance with AS4037, Section 3 and table 7.3. Where table
7.3 does not require NDE for a given pipe class, the vendor’s inspector and the Engineer
shall reserve the option of performing verification or additional NDE to ensure quality
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standards are maintained. The locations of the welds to be tested shall be selected by the
Engineer.
5. Visual examination and NDE shall be performed to the extent detailed within the above
table. The Vendor and the Engineer shall also take into consideration any additional
requirements for each specific application in line with AS 4041 and AS 4037.
6. This table is only representative of circumferential butt-welded joints, fillet welds and socket
welds as detailed in AS4037. All other welds shall be examined in accordance with Section
3 and Table 7.3 of AS4037.
8.12.1.1 NDE Reports and Welding Records
As a minimum all visual inspection and NDE reports shall conform to the requirements of AS
4037, Section 14.
Non-destructive examination reports shall contain the following information as a minimum:
 Drawing reference;
 Unique weld number on weld map;
 Welder identification;
 Weld type;
 Welding Process;
 Date of Test;
 Welding Procedure Specification;
 Exact position of the test area;
 Full detail of defective area, as applicable;
 Testing Company and Technician;
 Method of Test;
 Testing Procedure;
 Statement of Compliance.
Records for welding shall contain as a minimum:
 Drawing reference;
 Unique weld number on weld map;
 Welder identification;
 Weld type;
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 Welding Process;
 Visual acceptance;
 Welding Consumable;
 NDE type required (If Any)
 Signature of Inspector
 Comments
8.12.1.2 Repair of Sub-Standard Welds
All welds failing to meet the permissible levels of imperfections allowed in
AS 4037 shall be removed or repaired to the satisfaction of the Principal, and then re-tested
using the same NDE method, along with two (2) extra samples of welds from the same welder
as applicable.
8.12.1.3 Fabrication Inspection
During fabrication, the Contractor and Subcontractor(s) shall permit the Engineer free access to
the fabricators works at all reasonable times for the purpose of carrying out inspections and
shall afford all necessary facilities for the carrying out of such inspections. Where pipework has
been checked and approved by the Engineer at the works before being delivered to site, such
approval shall not relieve the Contractor of his responsibility to provide correct fitting on site.
8.12.1.4 Inspection during Erection
The Contractor shall give the Engineer 24 hours’ notice for inspections nominated as Witness or
Hold Points on the Contractor’s Inspection and Test Plan (ITP), or where the Engineer’s
approval is required for commencement of any stage of the works.
All field bolting and field welding shall be inspected during erection. All field weld slag shall be
removed prior to inspection.
Priming and painting in the vicinity of welds shall not be carried out over any field welding until
they have been visually, NDE and hydrostatically tested in accordance with specification.
8.12.1.5 Qualification Requirements for NDE and Inspection Personnel
Visual inspection shall be undertaken by a welding inspector qualified in accordance with

AS4041 (WTIA, CBIP, CSWIP or similar). Qualifications of inspection personnel shall be
submitted to the Engineer for approval prior to any works being undertaken. Inspection shall be
performed by personnel not involved in the supervision of the welded fabrication. Visual
inspection also includes the inspection of the weld preparation.
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Non-destructive testing shall be undertaken by technicians that are fully qualified for the
respective testing to be undertaken. Qualifications are to be to AINDT, PCN or similar. Copies
of the technician’s certification shall be submitted to the Engineer for approval prior to any works
being undertaken.
8.13.2 Pressure Test Requirements
Pressure testing shall be carried out in accordance with the requirements of AS 4041, AS 2032,
AS 2566 and this specification, except on fire service applications where the applicable
standards shall be adhered to.
Pressure piping includes all piping designed to convey or contain process or utility fluids at
either a positive or negative internal pressure and shall be tested as follows:
 Shop hydrostatic testing of piping spools shall not be required, unless specified
otherwise on the drawings.
 Shop hydrostatic testing is required for piping spools that require galvanising. The
spools shall be hydrostatically tested prior to galvanising.
Pressure piping shall be either hydrostatically or pneumatically tested in accordance with this
specification; only pneumatic pipe work shall be pneumatically tested.
The test pressures shall be as noted in this specification for the relevant pipe class.
Compressed air shall only be used to pressure test the compressed air pipe system following
written approval to do so and written approval of the test procedure that contains full details of
safety precautions by the Principal.
Open-ended vent, drain and similar piping systems operating at atmospheric pressure are not
considered as pressure piping and shall not be pressure tested but shall be leak tested by filing
the lines with water with an additional 1m column of water above the highest point in the system
and held for a minimum of 30 minutes to allow inspection.
Piping systems to be tested shall be divided into sections referred to as ‘test sections’.
‘Test section’ documentation shall contain isometrics of relevant sections of pipe work related to
the section of piping system that is being tested and shall include the following information:
 Limit of test as illustrated on the P&IDs or piping drawings.
 Location and thickness of test spades.
 Test medium.
 Test pressure.
 Location of vents and drains.

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 Requirements for isolation or removal of inline equipment and instruments.
The testing procedure shall be submitted to the Principal for approval.
Whilst the hydrostatic test is in progress the Contractor shall walk the test section of pipe line
and thoroughly inspect the piping system and components for leaks.
Reinforcing pads shall be tested with air at 34 kPa gauge (5 psig). All weld surfaces on the
inside and outside shall be swabbed with a leak testing solution. After testing is complete, the
vent hole shall be plugged with grease or silicon sealant. A record of all reinforcing pad tests
shall be maintained.
Short pieces of pressure piping which must be removed to permit installation of test blinds shall
be tested separately.
Flanged connections at points where blinds are used during pressure tests do not require
separate tests. After completion of testing the blinds shall be removed and the flanged
connection made good and thoroughly inspected after completion to assure tightness.
8.12.2.1 Carbon Steel and Stainless Steel Piping
All carbon steel and stainless steel piping and fittings shall be subject to a hydrostatic pressure
test as specified in the design code used for the pipeline, either AS 4041, AS 2885.1, AS 2419.1
or AS 1579, and applicable Pipe Class Data Sheets.
8.12.2.2 Polyethylene Piping
For testing of polyethylene piping the hydraulic test pressure shall be no less than the rated
maximum allowable working pressure for the pipeline pressure class being tested times 1.25, at
the specified temperature as listed in the piping class data sheets. Pipe shall be tested with full
compliance with AS2566 with the following additional requirements over and above the
specification;
 The test procedure shall include a calculation of the anticipated reduction or increase
in test pressure due to pipe elongation or contraction including the effects of diameter
reduction (or expansion) from ambient temperature changes and also strain due to
pressure. The appropriate time based elastic modulus and poisons ratio shall be
used. This gives indication whether changes in pressure are due to pipe leakage and
entrapped air or due to changes in test volume. Elongation due to application of
pressure should only cause an increase in volume of less than 1% and hence a
reduction in pressure of less than 1%. Elongation due to thermal expansion should
also only cause an increase in volume of less than 1% and hence a reduction in
pressure of less than 1%.
A record shall be kept of the time durations of the pressurising, depressurising and re-
pressurising phases of the test and all observations made.
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8.12.2.3 UPVC and Aquamine Pipe Systems
Both pressure and waste UPVC pipe systems shall be tested in line with the applicable
Australian Standards and pipe class Data Sheets.
8.12.2.4 Mining and High Pressure Hose
Both mining hose and high pressure hose pipe systems shall be tested in line with the
applicable Australian Standards and pipe class Data Sheets.
8.12.2.5 Hydrostatic Test Media
For hydrostatic testing of all piping systems other than compressed air systems, the test
medium shall be potable water at ambient temperature with pH value between 6.5 and 8.5.
8.13.3 Pneumatic Testing – Pneumatic Pipe Work Only
Testing of pneumatic pipe work systems shall be carried out using either dry nitrogen or clean,
dry and oil free compressed air with prior approval for such testing to be obtained from the
Principal.
Pneumatic test shall be performed in accordance with AS 4041, AS 4037 and the additional
requirements of this specification:
 Pipe systems only shall be pneumatically tested; vessels, filters, driers, compressors,
etc. shall be disconnected from piping systems to be pneumatically tested.
 Area of test shall be roped off and access into the area limited.
 The minimum metal temperature during a pneumatic test of piping shall not be less
than the temperature required by the engineering design.
 Piping system to be tested shall be protected by a safety valve.
 Set pressure of safety valve: Test pressure plus the lesser of 70 kPa or 7% of the test
pressure.
 Weak soapy water shall be used for testing for leaks.
8.13.4 Test Duration
The test pressure as specified for the individual pipe class shall not show a rate of decline of
more than 1% for the time period as specified by the relevant design code or nominated by the
Principal. The test period shall commence with the disconnection of the pressure source and
the reading and recording of the initial pressure on dual pressure gauges.
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Where no test duration is specified by the relevant design codes, or nominated by the Principal,
the default test duration, subject to approval by the Principal, shall be for a minimum period of
one (1) hour to enable thorough inspection of the piping system and components for leaks and
monitoring of pressure drop as specified above.
8.13.5 Preparation for Testing
All joints in a test section shall be accessible during tests and shall not be painted, insulated,
backfilled or otherwise covered until satisfactory completion of testing in accordance with this
specification unless written prior approval is obtained from the Principal.
All vents and other connections which can serve as vents shall be open during filling so that all
air is vented prior to applying test pressure to the system. Test vents shall be installed at high
points.
Equipment which is not to be subjected to pressure test shall be either disconnected from the
piping or blocked off during the test. Safety valves and control valves shall not be included in
site pressure testing.
Temporary spades and blanks installed for testing purposes shall be designed to withstand the
test pressure without distortion. Presence of spades shall be clearly visible during testing.
All control valves shall be removed or replaced with temporary spools or blinded off during
pressure testing.
Check valves shall have the flap or piston removed for testing, where pressure cannot be
located on the upstream side of the valve. The locking device of the flap pivot pin shall be
reinstated together with the flap and a new cover gasket shall be installed after completion of
the test.
Spring supports shall be restrained or removed and expansion bellows removed during
hydrostatic testing.
Drain points for fluid disposal after testing, shall be provided.
Care shall be taken to avoid overloading any parts of the supporting structures during
hydrostatic testing.
Piping which is spring or counterweight supported shall be blocked up temporarily to a degree

sufficient to sustain the weight of the test medium. Holding pins shall not be removed from
spring supports until testing is completed and the system is drained.
Pressure in the system shall be introduced gradually until the pressure is lesser of one-half of
the test pressure or 170 kPa gauges. Maintain pressure for 10 minutes and then gradually
increase pressure in steps of one tenth’s of the test pressure until the test pressure is attained.
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8.13.6 Test Equipment
Equipment to be used during testing shall have suitable capacity for the range of test pressures
required. All pressure gauges and chart recorders shall have been calibrated within 60 days
prior to testing and shall have current calibration certificates. The gauges shall be of a minimum
face size of 150 mm in diameter and ranged to approximately twice the test pressure.
A minimum of two gauges shall be provided for each test system. One gauge shall be located
at the highest point and the other at the pump or grade.
8.13.7 Completion of Testing
Pressure test shall be considered complete when:
 All defective welds, defective materials, flange leaks, valve gland leaks or other such
defects have been corrected and accepted by the Principal.
 All documentation and ‘test section’ information is complete and accepted by the
Principal.
 All temporary test blinds or spades and strainers have been removed, new gaskets
installed and the piping system reinstated.
Sealing materials shall not be used to correct leaks at joints. Valve glands shall not be
tightened to the extent that the valve cannot be operated.
After hydrostatic testing of the system is complete and approved by the Principal, all lines and
equipment shall be completely drained of the test fluid. Piping system vents shall be opened
while draining to avoid a vacuum. Care shall be taken when draining the test fluid to avoid
damage to other items of equipment. Special attention shall be given to points where water
may be trapped, such as in valve bodies or low points.
8.13.8 Test Records
Records for piping which require that pressure be held for a specified period of time shall
include any corrections of test pressure due to temperature variations between the start and
finish of the test.
Records of all tests carried out and approved by the Principal shall be retained in the job
records.
8.14 Cleaning And Re‐Instatement
8.14.1 Cleaning
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Completed systems shall be internally cleaned to remove all remaining foreign matter by water
flushing or blowing with air. Piping and equipment shall be dried if required.
8.14.2 Reinstatement
After successful completion of pressure testing, the Contractor shall return the piping system to
a state of commissioning readiness.
9. VALVE SPECIFICATION
9.1 General
Valves shall be as specified on the Valve Data Sheets in this specification. Valve types not
included in the Valve Data Sheets may be used subject to written approval by the Principal.
Actuated isolation and control valves shall be in accordance with the applicable instrument data
sheets.
Valve flanges shall be in accordance with ASME standards as specified in the valve data
sheets, unless otherwise approved by the Principal.
Flanged connections for valves shall use flanges to ANSI/ASME B 16.5 for all sizes up to DN
600 in line with requirements specified in Sections 8.1.3 and 8.1.4.
All valves installed in both potable and raw water systems shall be as specified in the individual
valve class data sheets in Section 10.2 and shall be installed in accordance with the relevant
regulatory and approvals requirements.
All valves installed in fire service applications shall be as specified in the individual valve class
data sheets in Section 10.2 and shall be installed in accordance with the relevant regulatory and
approvals requirements.
NPT threaded connections for valves up to and including DN50 and flanged connections for
valves DN80 and above are preferred, with the exception of diaphragm valves that shall all be
flanged connections, in line with valve data sheets.
DN32, 65, 90, 125 and 550 valves shall not be used.
Any variation from this specification or the use of valves that are not listed shall be approved by
the Principal prior to installation.
All valves attached to PE and PVC pipe work shall be supported such that no undue strain is
placed on the pipe work.
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All valves, including gate (sluice) valves, knife gate valves, butterfly valves and diaphragm
valves, shall be closed by a clockwise rotation of the hand wheel (arm) when looking at the face
of the hand wheel (arm).
Valves shall be installed in line with the latest version of related manufacturers data,
specifications and instructions
Spacer rings shall be installed with butterfly and non-return valves installed in HDPE, PVC or
Aquamine pipe systems.
9.2 Valve Numbers
9.2.1 Valve Size and Class Designation
Valve types shall be as shown on the P&ID and any valve lists to identify valve size and valve
class in line with the following format:
JJJ KKK
Valve Class
Nominal Valve Size
Where:
JJJ: Is the Nominal Valve Size (diameter), in mm.
KKK: Is the Valve Class
Example: 200 GA2 is a 200mm nominal diameter Gate Valve, class GA2.
Note:
1. For actuated values the valve size and class is not shown on the P&ID and should be
obtained from the instrument and valve list.
2. For manual valves the valve size and class is shown on the P&ID as the only label against a
manual valve on the P&ID and also shown in the valve list, unless the valve is designated as
a lockable isolation valve in which case the Equipment Prefix Code, Equipment Facility
Identifier and Sequential No., -AAYGGG will also be shown.
3. For both actuated and manual valves the valve size and class are shown on the
Instrument/Equipment Tag, as the first line. See Section 9.2.4 of this Specification 100-SP-
PI-0001, for Valve Tag Details.
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9.2.2 Actuated Isolation and Control Valves
Actuated isolation and control valves shall be numbered in accordance with FMG Equipment
Numbering Specifications Types A, B, or C.
9.2.3 Manual Valves
Manual valves shall be numbered in accordance with FMG Equipment Numbering

Specifications Types A, B, or C.
9.2.4 Valve Tag Details
A permanently attached stainless steel tag(s), 50mm diameter, minimum 1.5mm thick, sharp
edges removed, and stamped with the following information in lettering as sized below, shall be
provided on each valve:
Tag: 50mm Dia. S/S

Valve Size & Class
Designation Number
(Section 9.2.1).
4mm lettering
200GA2
TAG No.
Tag No. - Actuated Valves,
(Section 8.2.2), Manual
PV 2340
Valves, (Section 9.2.3). 6mm lettering
Note: Tag shall be permanently fixed to each valve via 1.6mm – 2.0mm stainless steel wire rope
with swaged joint or similar as approved by the Principal.
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100-SP-PI-0001_Rev 3
CONTROL VALVES MANUAL VALVES
Valve Size & Class Valve Size & Class

Designation Number Designation Number
(Section 9.2.1) as per (Section 9.2.1) as per
P&ID/Instrument & Valve P&ID/Valve list.
List.
200GA2 200GA2
TAG No. TAG No.

PV 2340 VA2340
Manual Valve Number,
Instrument Number, AAYGGG as per Valve
TVWX-YGGG as per list, (Section 9.2.3).
P&ID/Instrument & Valve
List, (Section 9.2.2).
9.3 Fire Service Valves
Valves for fire service installation shall be as specified in the Valve Data sheets and on
approved Project P&ID drawings.
The following details shall apply to fire service valves:
 Isolation valves shall be permanently identified to show their function and normal
operating position. They shall be secured or locked in the operating position and have
tag plates (as specified in AS2118, AS 2419 and AS2441).
 Butterfly valves used for pump isolation shall not be used on the suction side of fire
water pumps. Multi turn type valves shall be used for this purpose.
9.4 Drain And Vent Valves
Vent valves shall be fitted at all fresh water, raw water and salt water system high points in the
piping systems.
All pipe drains shall be located at low points in the pipe systems, with the drain valve pointing
down.
Manual vent and drain valves shall be DN25 ball valve unless otherwise stated on design
drawings, with all such valves as per Valve Class BA1 or BA2 depending on size.
Automatic air release and vacuum break valves shall be DN50 unless stated otherwise on
design drawings, with all such valves as per Valve Class AV1.
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100-SP-PI-0001_Rev 3
Each automatic air release and vacuum break valve installation shall incorporate a same sized
ball valve for isolation as per Valve Class BA1 or BA2 depending on size.
Figure 1: High Point Drain

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100-SP-PI-0001_Rev 3
Figure 2: Low Point Drain
9.5 Isolation Valves
All isolation valves shall be capable of being locked.
Intermediate isolation valves shall be installed on long pipe runs. The position and spacing of
such valves are to be in accordance with design drawings.
All isolation valves shall be above ground level unless stated otherwise on drawings or
approved by the Principal.
All main isolation valves for water duty shall be gate valves unless otherwise specified on
design drawings. Butterfly valves shall not be used as main isolating valves for water duty
unless otherwise specified on design drawings or with written approval by the Principal.
9.6 Access To Underground Valves
All valves shall be readily accessible. All hand operators shall be within 1.5m above floor level
to 0.4m below floor level with the preferred height being 1.1m above floor level.
All underground valves shall be of the “sluice valve” type as per Valve Class GA3 and shall be
install with a valve surface box arrangement as shown below for operation via an extension
stem.
The recommended surface box is supplied by Crevet – “CI Sluice Valve Box – Vic” and
incorporates the below designated surface box and reinforced concrete surround.
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Alternative surface box arrangements may be used subject to prior approval by the Principal.

Page 98 of 236
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9.7 Underground Valve Access Protection
Underground valve access surface boxes shall be protected from traffic by four steel bollards
painted Y14, Golden Yellow (AS2700) and Black in 200mm Bands, concrete filled and
concreted in the ground as detailed below. Refer to CO-00000-DR-CI-0004 for further details.
Depending on the location and hazards surrounding the valve, the bollards should be increased
in diameter, up to DN200, or decreased to 114.3mm.
Notes:
 FOR CONCRETE NOTES AND INDEX REFER DRAWING CO-00000-DR-CI-0001
 BOLLARDS SHALL BE PAINTED IN ALTERNATING 200mm WIDE BANDS OF

BLACK AND GOLDEN YELLOW (Y14 TO AS2700)
 CAST IN SLEEVE SHALL BE HOT DOP GALVANISED IN ACCORDANCE WITH

SPECIFICATION 100-SP-ST-003
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9.8 Valve Operators
9.8.1 Manual Operators
Geared operators shall be furnished for valves as detailed in the applicable valve data sheets.
Valves located on pipe racks beyond reach of a walkway shall be provided with extension stems
or chain operators so that they can be operated from the walkway.
All valve operators shall be lockable and indicate valve disc, ball or gate location/state.
All valve operators shall be able to be fitted with proximity switches.
9.8.2 Pneumatic Operators – “On/Off” Service
Pneumatic operators for all valves, excluding Valve classes BF1, BF2, KG1 and KG2, shall be
as specified on Project P&ID Drawings and on specific instrument data sheets.
Pneumatic operators for Valve Classes BF1, BF2, KG1 and KG2 shall be as specified in the
corresponding Valve Data Sheets in Section 10.2, unless otherwise specified on a specific
instrument data sheet.
Solenoid valves for pneumatic control of the pneumatic operators as listed in the Valve Data
Sheets in Section 10.2 are specifically listed as IP67 rated for use in a wet plant environment
with heavy wash down water hose jets.
Pneumatic valves for the control of all pneumatic operators shall be as per those listed for Valve
Classes BF1, BF2, KG1 and KG2 in the corresponding Valve Data Sheets in Section 10.2,
unless otherwise specified on a specific instrument data sheet or approved by the Principal.
9.9 Surface Protection And Identification
Valves shall be painted in the manufacturers standard paint system and colour with critical
components and functions protected during painting to ensure operation and ease of basic
maintenance.
9.10 Gland Seal Water Station
Each gland water station shall be fabricated and installed in line with the applicable Project
P&ID and Design drawings in relation to type, specified flow rate via Maric valve, components,
maximum operating pressure rating and configuration, unless otherwise approved by the
Principal.
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Where Gland Seal Water Stations are allocated a Tag Number on Project P&ID drawings, this
Tag Number and its corresponding Set Pressure and Flow Rate shall be stamped or engraved
on a 2.0mm thick stainless steel identification plate with 10mm lettering for the Tag Number and
6mm lettering for the Set Pressure and Flow Rate. The identification plate shall be bolted with
stainless steel bolts (or similar) to the front of the Gland Seal Water Station frame.
Individual items of each gland seal water station shall have allocated tag numbers identified in
line with Section 9.2.
Interconnecting hoses for Supply and discharge for the Gland Seal Water Stations shall be
Piping Class H2, and as per Project P&ID and Design Drawings.
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10. DATA SHEETS
10.1 Piping Class Data Sheets
10.1.1 Piping Class A1 – Aquamine
Piping Class A1 Page 1 of 2
SERVICE: Potable Water (PO) Raw Water (RW) Process Water (PW)
Saline Water (SW)
DESIGN Temperature: Application specific as detailed below

CONDITION:
Pressure: Application specific as detailed below
Test Pressure: 130% of specific application pressure rating as detailed below
CODE FLANGE RATING MATERIAL LOCATION CORROSION ALLOWANCE
AS 4041 Above or Below
Class 150 Aquamine PVC ground Nil
AS 3500
SIZE DESCRIPTION STANDARDS
PIPE GENERAL DN 100-300 Victaulic Aquamine PVC spline type joined pipe ASTM D2241
system – PVC1120
Below Ground Installation Above Ground Installation

Pressure
Pipe Size SDR Rating Test
@ 23ºC Pressure Pressure Test Pressure @
Pressure @
Rating @ 30ºC Rating @ 50ºC 50ºC
30ºC
DN100 9 3447 kPa 2757 kPa 3584 kPa 1309 kPa 1701 kPa
PIPE DETAIL
DN200 12.4 2413 kPa 1930 kPa 2509 kPa 916 kPa 1190 kPa
COUPLINGS & DN 100-300 Aquamine couplings and fittings, high ASTM D 3139
FITTINGS impact PVC 1120 defined as type 1, ASTM D-1784
grade 1 (class 12454-B) ASTM F-477
FLANGES DN 100-300 Aquamine flange couple with Class ASME B 16.5

150 ANSI flange, FF
GASKETS All Gasket Material – KLINGERlastic ASME B 16.21

elastomers > NBR - Nitrile
Thickness – 3.0mm
Gasket Style – IBC Ring gasket
Or approved equivalent
Page 102 of 236
100-SP-PI-0001_Rev 3
Piping Class A1 Page 2 of 2
BOLTING All Stud bolts; continuous thread; unified ASTM A 193 GR B7; ANSI/ASME B 1.1
coarse thread
Two (2) heavy hexagonal nuts per stud ASTM A 194 GR 2H; ANSI/ASME B 1.1
bolt; unified coarse thread
BRANCH All As per manufacturers catalogue

CONNECTIONS
Valves Isolation Throttling Non – Return Miscellaneous
DN100-150 BA2, BF1, GA2, GA3 BF1 NR2, NR3 AV2

DN200-300 BF1, GA2, GA3 BF1 NR2, NR3 AV2
REMARKS:
1. Valves listed in the above Valve Table for this Piping Class are for general service use for the full pressure range of this
Piping Class, however all listed valves are not necessarily suitable for all listed fluid classes. Valves shall only be used on
Fluid Class and duty applications as approved in the individual Valve Data Sheets in Section 10.2.
2. Valves not listed in the above Valve Table for this Piping Class shall only be used with prior approval by the Principal on an
individual basis, or as designated on approved Project P&ID drawings. This includes instances where an individual pipe
system’s absolute maximum operating pressure will be lower than that specified for this Piping Class, thus allowing suitably
lower pressure rated valves to be used as listed in Section 10.2.
3. Pipe system is to be installed in line with latest application and installation literature in relation to specific applications,
pressure ratings, installation and assembly instructions, while in adherence with all relevant codes and standards.
4. Valves of Class BF1 shall only be installed between mating flanges and shall not be installed as end of line valves
5. All below ground flange connections with galvanised steel backing rings shall be Denso Wrapped as per Sections 8.1.20 to
8.1.21
6. Spacer rings shall be fitted with butterfly valves and non-return valves for ease of operation.
7. Flange connections as per details included in this data sheet and Sections 8.1.3 to 8.1.5, including bolt torques.
8. On all bolting Loctite Nevasieze or approved equal to be used
9. PTFE tape or thread seal compound shall be used on all threaded connections
Page 103 of 236
100-SP-PI-0001_Rev 3
10.1.2 Piping Class C1 – Carbon Steel (Std. Wt.)
Piping Class C1 Page 1 of 2
SERVICE: Process Water (PW) Gland Seal Water (GW) Plant Air (PA) Instrument Air (IA)
Oily Water (OW) Waste Water (WW) Chilled Water (CW) Raw Water (RW)
Engine Coolant (EC) Waste Engine Coolant (WC)
DESIGN Temperature: 0 - 90°C
CONDITION:
Pressure: 1,600 kPa (g)
Test Pressure: 2,400 kPa (g) hydrostatic
AS 4041 Class 150 Carbon Steel Above or Below 2.0 mm
ground

PIPE DN 15-50 SMLS; Sch. 80; NPT API 5L GR B; ANSI/ASME B 36.10
DN 80-600 ERW Std. Wt; BW API 5L GR B; ANSI/ASME B 36.10 & B 16.25
FITTINGS DN 15-50 Forged; 3000#; NPT ASTM A 105; ANSI B 16.11;
DN 80-600 SMLS; Sch. to suit pipe; BW ASTM A 234 GR WPB; ANSI/ASME B 16.9
ELBOW RADIUS DN 15-600 Elbow shall be long radius, unless ANSI/ASME B 16.9
otherwise specified on project design
drawings or approved by Principal.
OLETS DN 15-40 Forged; Class 3000 Threadolet ASTM A 105

DN 15-80 Forged; Sch. to suit branch; BW ASTM A 105
FLANGES DN 15-50 RF, NPT ASTM A 105; ANSI/ASME B 16.5

(FF by exception DN 80-600 RF SO. (General) ASTM A 105; ANSI/ASME B 16.5
per 8.2.2)
DN 80-600 WN, FF. (Butterfly, Non-return valves)
ORIFICE DN 25-600 WN; Class 300; RF ASTM A 105; ANSI/ASME B 16.36

FLANGES
GASKETS All Gasket Material – KLINGERsil C6327 ASME B 16.21

Thickness – 1.5mm
coarse thread
BRANCH All See Piping Branch Connection Table in

CONNECTIONS Section 8.3.10 Table 17
Page 104 of 236
100-SP-PI-0001_Rev 3
DN15-50 BA1, BA4, BF1, GA1 BF1 NR1, NR2 AV1

DN80-150 BA2, BF1, GA2, GA3 BF1 NR2 AV2
DN200-300 BF1, GA2, GA3 BF1 NR2 AV2
DN350-600 BF2, GA2, GA3 BF2 NR2, NR3 -
REMARKS:
3. Mating flanges for butterfly valves shall be of the Weld Neck type
4. Ensure all pneumatic pipe work falls toward drain points to minimise condensation build up in the pipe work
5. Valves of Class BF1 and BF2 shall only be installed between mating flanges and shall not be installed as end of line
valves
7. All below ground pipe work shall be buried and Denso Wrapped as per Sections 8.1.20 to 8.1.21
10. Where “BW” or “SW” piping in sizes DN15 – 50 and threaded valves are installed, break flanges, or other, shall be installed to
allow removal and replacement of valves.

Page 105 of 236
100-SP-PI-0001_Rev 3
10.1.3 Piping Class C2 – Carbon Steel (Std. Wt. Victaulic)
SERVICE: Process Water (PW) Gland Seal Water (GW) Oily Water (OW)
Waste Water (WW)

CONDITION:
CODE FLANGE MATERIAL LOCATION CORROSION ALLOWANCE
RATING
AS 4041 Class 150 Carbon Steel – Std. Wt., Above or 1.5mm
AS 2419 Roll Grooved Victaulic System Below ground
AS 2941
PIPE DN 80-300 Victaulic IPS or AGS cut or rolled API 5L GR B; ANSI/ASME B 36.10
groove carbon steel pipe – Std. Wt.
DN 350-600 Victaulic AGS rolled groove only carbon
steel pipe – Std. Wt.
COUPLINGS
General Couplings DN 80-300 Victaulic Style 07 or Style 77 ASTM A 536, ASTM F 1476
DN 350-600 Victaulic Style W07 or Style W77 ASTM A 536, ASTM F 1476
Reducing Couplings DN80-200 Victaulic Style 750 reducing couplings ASTM A 536, ASTM F 1476
Snap-Joint Quick DN80-200 Victaulic Style 78 Snap Joint couplings ASTM A 536, ASTM F 1476
Disconnect
Couplings
Branch Connections DN80-200 Victaulic Style 920 and 920N ASTM A 536, ASTM F 1476
mechanical –T outlet, NPT or Grooved
outlet connection
DN80-150 Victaulic Style 72 outlet couplings, NPT ASTM A 536, ASTM F 1476
or Grooved outlet connection
FITTINGS DN 80-300 Victaulic IPS fittings ASTM A 536, ASTM F 1476
DN 350-600 Victaulic AGS fittings ASTM A 536, ASTM F 1476
FLANGES DN80-300 Flanged adaptor nipple No. 45R, ANSI ANSI/ASME B 16.5
(FF by exception per Class 150, RF
8.2.2)
DN350-600 Flange adaptor nipple No. W45R, ANSI ANSI/ASME B 16.5
Class 150, RF
DN 80-600 Victaulic, Vic-Flange adapter Style 741, ANSI/ASME B 16.5

ANSI Class 150, RF
Page 106 of 236
100-SP-PI-0001_Rev 3
GASKETS
Couplings Standard Style, Victaulic Grade “E” ANSI/NSF 61

EPDM coupling gaskets
PW & GW Duty Flange Gasket Material – KLINGERsil C6327 ASME B 16.21

connections Thickness – 1.5mm
Couplings Standard Style, Victaulic Grade “T” ANSI/NSF 61
Nitrile coupling gaskets
OW & WW Duty Flange Gasket Material – KLINGERsil C6327 ASME B 16.21

BOLTING Couplings Victaulic standard bolting

All flange Stud bolts; continuous thread; unified ASTM A 193 GR B7; ANSI/ASME B 1.1
connections coarse thread
DN80-150 BA2, BA3, BF1, BF3, BF1, BF3 NR2, NR4 AV2
GA2, GA4
DN200-300 BF1, BF3, GA2, GA4 BF1, BF3 NR2, NR4 AV2
DN350-600 BF2, BF4, GA2 BF2, BF4 NR2, NR3 -
REMARKS:
4. Flange washers shall be used as required by Victaulic specifications and requirements for flange adaptors
pressure ratings, installation and assembly while in adherence with all relevant codes and standards.
6. Pipe grooving and installation shall be performed by personnel who have been trained by a Victaulic factory trained
representative who shall provide periodic review of system installation with any identified defects to be rectified
7. All pipe system components shall be on the one manufacturer
valves
9. All below ground pipe work shall be buried and Denso Wrapped as per Sections 8.1.20 to 8.1.21
Page 107 of 236
100-SP-PI-0001_Rev 3
10.1.4 Piping Class C3 – Carbon Steel (Sch. XS.)
SERVICE: Slurry (SL) Tailings TL

CONDITION:
Test Pressure: 3,600kPa (g) hydrostatic
AS 4041 Class 300 Carbon Steel – Extra Strong Above ground 2.0 mm

PIPE DN 15-50 SMLS; Sch. 80 BE, NPT or Plain API 5L GR B; ANSI/ASME B 36.10 & B 16.25
DN 80-450 ERW; extra strong; BE API 5L GR B; ANSI/ASME B 36.10 & B 16.25
FITTINGS
Elbows DN 15-50 Forged 3000# NPT or SW ASTM A 105; ANSI B 16.11
Wrought; SMLS Sch to suit pipe; BW ASTM A 234 GR WPB; ANSI/ASME B 16.9
DN 80-450 SMLS; extra strong; BW; LR API 5L GR B; ANSI/ASME B 16.9
Tees DN15-50 Forged 3000# NPT or SW ASTM A105; ANSI B 16.11
DN 80-450 SMLS; extra strong; BW API 5L GR B; ANSI/ASME B 16.9
Reducers DN15-50 Forged 3000# NPT or SW ASTM A105; ANSI B 16.11
DN 80-450 SMLS; extra strong; BW ASTM A 234 GR WPB; ANSI/ASME B 16.9
FLANGES DN 80-450 Class 300; RF; SO or WN ASTM A 105; ANSI/ASME B 16.5

(FF by exception
per 8.2.2)

Thickness – 1.5mm
coarse thread

DN15-50 BA1 - - -
DN80-300 - - NR6 -
DN350 - - NR6 -
Page 108 of 236
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REMARKS:
Page 109 of 236
100-SP-PI-0001_Rev 3
10.1.5 Piping Class C4 – Carbon Steel, (Sch. XS. Victaulic)
SERVICE: Slurry (SL) Tailings (TL)

CONDITION:
AS 4041 Class 300 Carbon Steel – Extra Strong Above ground 1.5mm
AS 2419 Victaulic System
AS 2941
PIPE DN 80-300 ERW, Sch. XS, cut groove carbon steel pipe API 5L GR B; ANSI/ASME B 36.10
Victaulic IPS coupling cut groove profile
DN 350-450 ERW, Sch. XS, roll groove carbon steel pipe API 5L GR B; ANSI/ASME B 36.10
Victaulic AGS coupling roll groove profile
COUPLINGS DN 80-300 Victaulic IPS Style 07 Rigid or Style 77 Std. Flexible ASTM A 536
Couplings - Painted
DN 350-450 Victaulic AGS Style W07 Rigid or Style W77 Flexible ASTM A 536
Couplings – Painted
FITTINGS DN 80-300 Victaulic IPS fittings ANSI/ASME B 16.5
DN 350-450 Victaulic AGS fittings ANSI/ASME B 16.5
ELBOW RADIUS DN 80-450 Elbow shall be long radius, unless otherwise ANSI/ASME B 16.9
specified on project design drawings or approved by
Principal.
FLANGES DN 80-300 Victaulic IPS flanged adaptor nipple No. 46R, ANSI ANSI/ASME B 16.5
(FF by exception Class 300, RF
per 8.2.2)
DN 80-300 Victaulic IPS flanged adaptor nipple No. 46F, ANSI ANSI/ASME B 16.5
Class 300, FF
DN 350-450 Custom AGS grooved Flanged Adaptor Nipple, ANSI/ASME B 16.5

ANSI Class 300, RF – similar to No. W45R.
Note: “SPECIAL”, Consult Victaulic
NOTE: Victaulic AGS couplings and the corresponding roll groove profile SHALL be used for all
pipe work, fittings and flanges as detailed above for all pipe work above DN300.
IPS couplings and fittings SHALL NOT be used for pipe work above DN300
Page 110 of 236
100-SP-PI-0001_Rev 3
GASKETS Couplings “Flush Seal” style Victaulic Grade “E” EPDM ANSI/NSF 61
coupling gaskets for both IPS and AGS couplings
Flange Gasket Material – KLINGERsil C6327 ASME B 16.21


All flange Stud bolts; continuous thread; unified coarse thread ASTM A 193 GR B7; ANSI/ASME
connections B 1.1
Two (2) heavy hexagonal nuts per stud bolt; unified ASTM A 194 GR 2H; ANSI/ASME
coarse thread B 1.1
Non –
Valves Isolation Throttling
Return
Miscellaneous
DN80-450 RD1 - NR6 -
REMARKS:
Page 111 of 236
100-SP-PI-0001_Rev 3
10.1.6 Piping Class C5 – Carbon Steel (Diesel Oil)
SERVICE: Diesel Oil (DO) , Engine Oil (EO), Gear Oil (GO), Hydraulic Oil (HO),
Transmission Oil (TO), Grease Low pressure (GRL), Waste Oil (WO)
CONDITION:
AS 4041 Class 150 Carbon Steel – Std. Wt. Above ground 2.0 mm
AS 1940

PIPE DN 15-40 Carbon steel, Std. Wt.; SMLS, plain API 5L GR B; ANSI/ASME B 36.10
ends
DN 50-600 Carbon steel, Std. Wt.; SMLS or ERW, API 5L GR B; ANSI/ASME B 36.10
bevel ends, butt weld
FITTINGS DN 15-40 Carbon steel, 3000# socket weld ASTM A 105; ANSI B 16.11
DN 50-600 Carbon steel, Std. Wt. butt weld ASTM A 234 GR WPB; ANSI B 16.9
drawings and approved by Principal.
FLANGES DN 15-40 Class 150; RF, SW, SO or WN ASTM A 105; ANSI/ASME B 16.5
(FF by exception DN 50-600 Class 150; RF, SO or WN ASTM A 105; ANSI/ASME B 16.5
per 8.2.2)

Thickness – 1.5mm
coarse thread

DN15-40 BA5, GA7 - NR5 -

DN80-200 BA5, BA9, GA5 - NR5 -
DN250-600 GA5, BA5 NR5
Page 112 of 236
100-SP-PI-0001_Rev 3
REMARKS:
1. Taper/taper threaded connections for DN15-50 may be allowed for instrument connections, thermal relief valves, drain valves,
vent valves and small bore ancillary piping, provided extra strong pipe is used and only with the approval of the Principal. All
other connections are to be flanged or socket welded.
2. Gasket material shall be chemically compatible for service
3. All valves shall be suitable and approved as required for fluid service
5. 10% NDT of all pipe and fanged welds shall be performed as a minimum in line with applicable AS 4041 piping class along with
all other requirements
7. All piping for fluids EO, GO, HO, TO, GRL shall be acid pickled and cleaned in accordance with AS1627.5.
Page 113 of 236
100-SP-PI-0001_Rev 3
10.1.7 Piping Class C5A – Diesel Twin Walled Pipe – 150
Piping Class C5A Page 1 of 2
SERVICE: Diesel Oil (DO)

CONDITION:
CODE FLANGE RATING MATERIAL LOCATION CORROSION
ALLOWANCE
AS 4041 Class 150 Primary Pipe: Carbon Steel –Std. Wt. Above ground (primary 2.0 mm
AS 1940 pipe only), below
Secondary Pipe: HDPE, Pressure ground with secondary
AS 2566 rating 200kPa containment (primary
and secondary pipe)

PIPE - Primary DN 15-40 Carbon steel, Std. Wt.; SMLS, plain ends API 5L GR B; ANSI/ASME B 36.10
DN 50-250 Carbon steel, Std. Wt.; SMLS or ERW, bevel API 5L GR B; ANSI/ASME B 36.10
ends, butt weld
PIPE - Secondary DN 125-400 HDPE, Pressure Rating 200kPa PE rating to AS 4131
FITTINGS - DN 15-40 Carbon steel, 3000# socket weld ASTM A 105; ANSI B 16.11
Primary
FITTINGS - DN 125-400 HDPE – Welded or heat-shrink connections
Secondary (see note 7)
specified on project design drawings and
approved by Principal.
FLANGES - DN 15-40 Class 150, RF, SO or WN ASTM A 105; ANSI/ASME B 16.5

Primary
(FF by exception DN 50-250 Class 150; RF, SW, SO or WN ASTM A 105; ANSI/ASME B 16.5
per 8.2.2)
FLANGES - DN 125-400 Vendor to advise
Secondary
GASKETS – All Gasket Material – KLINGERsil C4430 ASME B 16.21

Primary Thickness – 1.5mm
GASKETS - All N/A N/A
Secondary
BOLTING All Stud bolts; continuous thread; unified coarse ASTM A 193 GR B7; ANSI/ASME B 1.1
thread
Two (2) heavy hexagonal nuts per stud bolt; ASTM A 194 GR 2H; ANSI/ASME B 1.1
unified coarse thread

CONNECTIONS - Section 8.3.10 Table 17
Primary
BRANCH
CONNECTIONS - Vendor to advise
Secondary
Page 114 of 236
100-SP-PI-0001_Rev 3
DN15-40 GA7, BA5 - NR5 -

DN80-200 GA5, GA7, BA5 - NR5 -
DN250-600 GA5,BA5 - NR5 -
Piping Class C5A Page 2 of 2
REMARKS:
1. Taper/taper threaded connections for DN15-50 may be allowed for instrument connections, thermal relief valves, drain valves,
vent valves and small bore ancillary piping, provided extra strong pipe is used and only with the approval of the Principal. All
other connections are to be flanged or socket welded.
7. Heat shrink connections for the secondary HDPE pipe shall be waterproof.

Page 115 of 236
100-SP-PI-0001_Rev 3
10.1.8 Piping Class C5B – Diesel Twin Walled Pipe – 300
Piping Class C5B Page 1 of 2
SERVICE: Diesel Oil (DO)

CONDITION:
Test Pressure: 6000 kPa (g) hydrostatic
CODE FLANGE RATING MATERIAL LOCATION CORROSION
ALLOWANCE
AS 4041 Primary Pipe: Primary Pipe: Carbon Steel –Std. Wt. Above ground (primary 2.0 mm
AS 1940 Class 300 pipe only), below
Secondary Pipe: HDPE, Pressure ground with secondary
AS 2566 rating 200kPa containment (primary
and secondary pipe)

PIPE - Primary DN 15-40 Carbon steel, Std. Wt.; SMLS, plain ends ASTM A106 Gr B; ANSI/ASME B 36.10
DN 50-250 Carbon steel, Std. Wt.; SMLS or ERW, bevel API 5L GR B; ANSI/ASME B 36.10
ends, butt weld
PIPE - Secondary DN 125-400 HDPE, Pressure Rating 200kPa PE rating to AS 4131
FITTINGS - DN 15-40 Carbon steel, 3000# socket weld ASTM A 105; ANSI B 16.11
Primary
FITTINGS - DN 125-400 HDPE – Welded or heat-shrink connections
Secondary (see note 7)
specified on project design drawings or
FLANGES - DN 15-40 Class 300, RF. SW, SO or WN ASTM A 105; ANSI/ASME B 16.5
Primary
(FF by exception DN 50-150 Class 300; RF, SO or WN ASTM A 105; ANSI/ASME B 16.5
per 8.2.2)
FLANGES - DN 125-400 Vendor to advise
Secondary
GASKETS – All Gasket Material – KLINGERsil C4430 ASME B 16.21

Primary Thickness – 1.5mm
GASKETS - All N/A N/A
Secondary
thread

CONNECTIONS - Section 8.3.10 Table 17
Primary
BRANCH Vendor to advise
CONNECTIONS -
Secondary

Page 116 of 236
100-SP-PI-0001_Rev 3
DN15-40 GA7, BA7 - NR5B -

DN50 GA6,BA7 - NR5B -
DN80-250 GA6,BA7 - NR5B -
Piping Class C5B Page 2 of 2
REMARKS:
1. Threaded connections shall not be used.
7. Heat shrink connections for the secondary HDPE pipe shall be waterproof.

Page 117 of 236
100-SP-PI-0001_Rev 3
10.1.9 Piping Class C6 – Carbon Steel, (Sch. XS, Slurry)

CONDITION:
AS 4041 Class 150 Carbon Steel – Extra Strong Above ground 2.0 mm

PIPE DN 15-50 SMLS; Sch. 80 BE, NPT or Plain API 5L GR B; ANSI/ASME B 36.10 & B 16.25
DN 80-450 SMLS or ERW; extra strong; BE API 5L GR B; ANSI/ASME B 36.10 & B 16.25
FITTINGS
Elbows DN 15-50 Forged 3000# NPT or SW ASTM A 105; ANSI B 16.11
DN 80-450 SMLS; extra strong; BW; LR API 5L GR B; ANSI/ASME B 16.9
Tees DN15-50 Forged 3000# NPT or SW ASTM A105; ANSI B 16.11
DN 80-450 SMLS; extra strong; BW API 5L GR B; ANSI/ASME B 16.9
OLETS DN 15-50 Forged; Class 3000 ASTM A 105
DN 80 Forged; Sch. to suit branch; BW ASTM A 105
FLANGES DN 80-450 Class 150; RF; SO or WN ASTM A 105; ANSI/ASME B 16.5

(FF by exception
per 8.2.2)

Thickness – 1.5mm
coarse thread

DN15-50 - - - -
DN80-300 - - NR6 -
DN450 - - NR6 -
Page 118 of 236
100-SP-PI-0001_Rev 3
REMARKS:
1. Piping Class C6 is schedule “Extra Strong” pipe with ANSI flanges to provide increased wear life only – not for
pressures higher than stated above.
5. On all bolting Loctite Nevasieze or approved equal to be used.
Page 119 of 236
100-SP-PI-0001_Rev 3
10.1.10 Piping Class C7 – (Large Diameter)
SERVICE: Process Water (PW)

CONDITION:
ASME B31.3 ANSI #150 Carbon Steel Pipe, Std Wt. Above ground 1.5 mm
ASME B16.47 AS 4087 – PN16
AS4087 AS4041
PIPE DN 15-50 SMLS, Sch 80, BE, NPT or Plain API 5L Gr B/ ASTM A 53 Gr B, ASTM A 672 Gr
‘C65’. DIM to ASME B36.10 & 16.25
DN80-600 ERW, Std Wt, BW
DN750-1200 ERW, SAW, BW Ends, Std Wt.
FITTINGS DN 15-50 Forged; 3000#, BW, NPT or SW ASTM A105; ANSI B 16.11
DN 80-600 Smls, Sch to suit pipe; BW ASTM A234 Gr WPB; ANSI/ASME B 16.9
OLETS DN 15-40 Forged, Class 3000, Thread –O-Lets ASTM A 105
DN 50-80 Forged, Class 3000, Weld –O-Lets ASTM A 105
Bends DN 750- ASTM A 234 Gr WPB, std. wt. DIM. to ASME B 16.9, BW, LR
1200 or
Tees DN 500-900 Fabricated from pipe material (note 5) DIM. to ASME B 16.9, BW,
Branches DN 15-50 Smls, Sch 80, BE, NPT or Plain. See API 5L GR B; ANSI/ASME B 36.10
(Stub-Ins) Section 8.3.10 Table 18
(Notes 5,6) DN 80-600 ERW Std. Wt; BW. See Section 8.3.10 API 5L GR B; ANSI/ASME B 36.10 & B 16.25
Table 18
DN 750- ERW, SAW, BW ENDS, Std. Wt. See ASME B31.3
1200 Section 8.3.10 Table 18
Reducers DN 750- ASTM A 234 Gr WPB, std. wt. ASME B16.9
1200 Fabricated from pipe material (note 5)
FLANGES DN 15-50 Class 150; RF, NPT or SW, (FF by ASTM A 105; ANSI/ASME B 16.5
exception per 8.2.2)
DN 80-600 Class 150; RF, SO or WN, (FF by ASTM A 105; ANSI/ASME B 16.5
exception per 8.2.2)
DN 750- ASTM A 105 Plate Flanges to material AS 4087, PN16, FF
1200 spec: AS 3678 Gr 250
BLIND FLANGES DN 15-600 Class 150; RF ASTM A 105, ANSI/ASME B 16.5
DN 750- ASTM A 105 ASME B16.47 series ‘A’, class 150, RF
1200
ASTM A 105/ASTM A 105/Plate Material AS4087, PN16, FF/Dim. std. to BS3293
AS3678 Gr 250 Thickness TBA

Thickness – 1.5mm WSA109 for AS 4087 Flanges
Gasket Style – IBC Ring gasket Flat face FLG joint shall have full face gasket
BOLTING All Stud bolts, continuous thread; unified ASTM A 193 GR B7; ANSI/ASME B 1.1/AS4087
coarse thread
Two (2) heavy hexagonal nuts per stud ASTM A 194 GR 2H; ANSI/ASME B 1.1/AS4087
Page 120 of 236
100-SP-PI-0001_Rev 3
DN500-600 BF2, GA2 BF2 NR3 -
REMARKS:
1. Flange connections as per details included in this datasheet along with AS 4087 or ANSI/ASME B 16.47 series ‘A’.
2. On all bolting Loctite Nevasieze or approved equal to be used.
3. All branches shall be tees or stub-in connections fabricated from pipe in accordance with ASME B 31.3 or AS 4041.
4. All piping of sizes ≤ DN 600 connecting to this pipe class shall be in accordance with piping class – C1. However the test
pressures shall be in accordance with this pipe class/line list.
5. All sketches for fabricated pipe fittings shall have to be approved by purchaser prior to fabrication
6. Reinforcing pad requirements for stub-in branch connections shall be in accordance with the branch table (sheet 2 of 2)
7. Valves listed in the above Valve Table for this Piping Class are for general service use for the full pressure range of this Piping
Class, however all listed valves are not necessarily suitable for all listed fluid classes. Valves shall only be used on Fluid Class
and duty applications as approved in the individual Valve Data Sheets in Section 10.2.
9. Flange connections as per details included in this data sheet along with AS 4087 and ANSI/ASME B 16.5.
Page 121 of 236
100-SP-PI-0001_Rev 3
10.1.11 Piping Class C8 – Carbon Steel (Sch. 80.)
SERVICE: Tailings (TL)

CONDITION:
AS 4041 Class 600 Carbon Steel – Sch 80 Above ground 2.0 mm

PIPE DN 15-50 SMLS; Sch. 80, Plain Ends API 5L GR B; ANSI/ASME B 36.10 & B 16.25
DN 80-450 ERW; Sch 80; BE API 5L GR B; ANSI/ASME B 36.10 & B 16.25
FITTINGS
OLETS DN 15-50 Forged, Class 3000, Sock –O-Lets ASTM A 105
Elbows DN 15-50 Forged 3000# SW / or ASTM A 105; ANSI B 16.11 / or
DN 80-350 SMLS; Sch 80; BW; LR API 5L GR B; ANSI/ASME B 16.9
Tees DN15-50 Forged 3000# SW / or ASTM A105; ANSI B 16.11 / or
DN 80-350 SMLS; Sch 80; BW API 5L GR B; ANSI/ASME B 16.9
Couplings DN 15-50 Forged 3000# SW ASTM A 105, ANSI B 16.11
FLANGES DN 15-50 Class 600, RF, WN ASTM A 105, ANSI/ASME B 16.5

(FF by exception DN 80-350 Class 600; RF, WN ASTM A 105; ANSI/ASME B 16.5
per 8.2.2)
GASKETS All Gasket Material – Klinger Maxiprofile ASME B 16.21

(Kammprofile) Gaskets – Type T109 –
LA1 or approved equivalent
coarse thread
BRANCH All See Piping Branch Connection Table

DN15-50 - - - -
DN80-300 - - - -
DN350 - - - -
Page 122 of 236
100-SP-PI-0001_Rev 3
REMARKS:
Page 123 of 236
100-SP-PI-0001_Rev 3
10.1.12 Piping Class C9 – Carbon Steel for Oil Services
SERVICE: Engine Oil (EO), Hydraulic Oil (HO), Gear Oil (GO), Transmission Oil (TO), Grease Low pressure (GRL)
Waste Oil (WO)

CONDITION:
Pressure: 1600 kPa (g) @ 60°C
Test Pressure: 2400 kPa (g)
AS 4041 Class 150 Carbon steel Above ground 0.5 mm
PIPE DN 15-50 Seamless Sch XS, plain ends ASTM A106 Gr B, ASME B36.10
DN 80-200 Seamless, Std Wt, BE ASTM A106 Gr B, ASME B36.10
GASKETS All Klinger Type CR Spiral Wound SS316 ASME B16.20

with PTFE filler, 3.2mm thick, inner &
outer ring
FITTINGS DN 15-50 Forged, Class 3000, SW ASTM A105, ASME B16.11
DN 80-200 Seamless, Std Wt, BW ASTM A234 WPB, ASME B16.9
BOLTING All Stud bolts; continuous thread; unified ASTM A 193 GR B7

coarse thread
Two (2) heavy hexagonal nuts per stud ASTM A 194 GR 2H

FLANGES DN15-50 WN, Class 150 RF, Sch XS Bore ASTM A105, ASME B16.5
(Notes 1, 2) DN80-200 WN, Class 150, RF, Std Wt Bore ASTM A105, ASME B16.5
BRANCH All See Branch Connection Table in

Valves Isolation Throttling Non-Return Miscellaneous
DN15-40 BA5,GA7, BA8 NR5
DN50-200 BA9,BA5,GA5 NR5
REMARKS:
1. Weld neck (WN) flanges ONLY to be used. FF flanges may be used by exception per 8.2.2).
2. Welded ends to suit pipe schedule and bevelled to ASME B16.25.
3. With the exception of pipework for WO fluid, pipework shall be acid pickled and cleaned in accordance with AS1627.5.
Page 124 of 236
100-SP-PI-0001_Rev 3
10.1.13 Piping Class D1 – Domestic Water
Piping Class D1 Page 1 of 1
SERVICE: Potable Water (PO) Raw Water (RW)

CONDITION:
AS 3500.1 NA As Required As Required Nil
General  Piping materials, valves and fittings shall comply with AS 3500.1:2003 and standards referenced
therein.
 Detailed design is the responsibility of the installation Contractor.
 Installation and testing shall comply with AS 3500.1.
 The complete installation shall comply with applicable statutory regulations including Plumbing
Code of Australia, and Water Service Licensing Regulations (2000).
 Galvanised steel pipe shall not be used (AS 3500.1 Cl. 2.4.2 (c))
 Rubber-ring jointed pipe shall not be used
 Polyethylene potable water lines DN100 or less shall be PN12.5 or greater (AS 3500.1)
Page 125 of 236
100-SP-PI-0001_Rev 3
10.1.14 Piping Class G1 – Galvanised Carbon Steel (Std. Wt.)
Piping Class G1 Page 1 of 2
SERVICE: Process Water (PW) Gland Seal Water (GW) Plant Air (PA) Instrument Air (IA)
Note 8,9
Fire Water (FW) Oily Water (OW) Waste Water (WW)
CONDITION:
AS 4041 Class 150 Galvanised Carbon Steel Above ground 2.0 mm
AS 2419
AS 2941
PIPE DN 15-50 SMLS; Sch, 80; NPT – Gal. API 5L GR B; ANSI/ASME B 36.10
DN 80-600 ERW; Std Wt; BW – Gal. API 5L GR B; ANSI/ASME B 36.10 & B 16.25
DN 650-1200 Carbon steel, XS; SMLS, plain ends – Gal. API 5L GR B; ANSI/ASME B 36.10 & B 16.25
FITTINGS DN 15-50 Forged; 3000#; NPT – Gal. ASTM A 105; ANSI B 16.11
DN 80-600 SMLS; Sch. same as pipe; BW – Gal. ASTM A 234 GR WPB; ANSI/ASME B 16.9
DN 650-1200 SMLS; Sch. same as pipe; BW – Gal. ASTM A 234 GR WPB; ANSI B 16.9
DN 650-1200 Elbow shall be short radius – Gal. ASTM A 105; ANSI/ASME B 16.28
OLETS DN 15-40 Forged; Class 3000; NPT Threadolet ASTM A 105
FLANGES DN 15-50 Class 150; RF; blind or NPT - Gal. ASTM A 105; ANSI/ASME B 16.5
(FF by exception DN 80-600 Class 150; Forged-Gal. RF, SO (General) ASTM A 105; ANSI/ASME B 16.5
per 8.2.2)
WN, FF ( Butterfly and Non –return)
DN 650-1200 Class 150; RF or FF, SO; Forged - Gal. ASTM A 105; ANSI/ASME B 16.47 Series A
ORIFICE DN 25-600 WN; Class 300; RF. ASTM A 105; ANSI/ASME B 16.36
FLANGES

GASKETS
coarse thread

DN15-50 BA1, BA4, GA1 BA1 NR1 AV1

DN80-150 BA2, BF1, GA2, GA3 BF1 NR2 AV2
DN200-300 BF1, GA2, GA3 BF1 NR2 AV2
DN350 BF2, GA2, GA3 BF2 NR2, NR3A -
DN400-500 BF2, GA2, GA3 BF2 NR3, NR3A -
Page 126 of 236
100-SP-PI-0001_Rev 3
DN600 BF2, GA2, GA3 BF2 NR3, NR3B -

DN 700 - 1200 GA2A, BF2 NR3B
REMARKS:
6. All welded components shall be hot dipped galvanized after fabrication.
7. Pipe and fittings DN80 and larger shall be fabricated as flanged spools and then hot dipped galvanised to AS 4792
8. This piping material class shall apply to all fire hydrant systems and interconnected hose reel systems. Sprinkler system
piping materials may also be in accordance with this piping class, but as a minimum shall comply with AS2118 / AS4118
(including pressure rating compatible with the site fire water supply and distribution). Where alternative piping materials are
used for sprinkler systems, valves shall be in accordance with this specification to minimise site spares holdings.
9. All materials and installation for fire system pipe work and valves shall conform to the applicable regulations
including AS2118, AS2419, AS2441, AS2941 and AS4118.
10. Butterfly valves used for pump isolation shall not be installed on the suction side of fire water pumps
valves
14. DN 80-600 sizes to be fabricated as max. 12m flanged spools.
Page 127 of 236
100-SP-PI-0001_Rev 3
10.1.15 Piping Class G2 – Galvanised Carbon Steel (Std. Wt. Victaulic)
Note 9,10
SERVICE: Process Water (PW) Gland Seal Water (GW) Fire Water (FW)
Oily Water (OW) Waste Water (WW)

CONDITION: Pressure: 1,600 kPa (g)
RATING
AS 4041 Class 150 Galvanised Carbon Steel – Std. Above 1.5mm
AS 2419 Wt., ground
AS 2941 Roll Grooved Victaulic System
PIPE DN 80-300 Galvanised Victaulic IPS or AGS cut API 5L GR B; ANSI/ASME B 36.10
or rolled groove carbon steel pipe –
Std. Wt.
Galvanised Victaulic AGS rolled
DN 350-600 groove only carbon steel pipe – Std.
Wt.
COUPLINGS
General Couplings DN 80-300 Gal. Victaulic Style 07 or Style 77 ASTM A 536
DN 350-600 Gal. Victaulic Style W07 or Style W77 ASTM A 536
Reducing Couplings DN80-200 Gal. Victaulic Style 750 reducing

couplings
Snap-Joint Quick DN80-200 Gal. Victaulic Style 78 Snap Joint

Disconnect couplings
Couplings
Branch Connections DN80-200 Victaulic Style 920 and 920N ASTM A 536, ASTM F 1476
mechanical –T outlet, NPT or
Grooved outlet connection
DN80-150 Victaulic Style 72 outlet couplings, ASTM A 536, ASTM F 1476

NPT or Grooved outlet connection
FITTINGS DN 80-300 Gal. Victaulic IPS fittings
DN 350-600 Gal. Victaulic AGS fittings
FLANGES DN80-300 Gal. Flanged adaptor nipple No. 45R, ANSI/ASME B 16.5
ANSI Class 150, RF
(FF by exception per
8.2.2) DN350-600 Gal. Flange adaptor nipple No. ANSI/ASME B 16.5
W45R, ANSI Class 150, RF
DN 80-600 Gal. Victaulic, Vic-Flange adapter ANSI/ASME B 16.5

Style 741, ANSI Class 150, RF
Page 128 of 236
100-SP-PI-0001_Rev 3
GASKETS
Couplings Standard Style, Victaulic Grade “E” ANSI/NSF 61
EPDM coupling gaskets
PW, GW & FW Duty connections
Thickness – 1.5mm
Couplings Standard Style, Victaulic Grade “T” ANSI/NSF 61
Nitrile coupling gaskets
OW & WW Duty connections
Thickness – 1.5mm
BOLTING Couplings Gal. Victaulic standard bolting

All flange Stud bolts; continuous thread; unified ASTM A 193 GR B7; ANSI/ASME B 1.1
connections coarse thread
Two (2) heavy hexagonal nuts per ASTM A 194 GR 2H; ANSI/ASME B 1.1
stud bolt; unified coarse thread
DN80-150 BA2, BA3, BF1, BF3, BF1, BF3 NR2, NR4 AV2
GA2, GA4
DN200-300 BF1, BF3, GA2, GA4 BF1, BF3 NR2, NR4 AV2
DN350-600 BF2, BF4, GA2, GA3 BF2 NR2, NR3 -
REMARKS:
used for sprinkler systems, valves and couplings shall be in accordance with this specification to minimise site spares
holdings.
including AS2118, AS2419, AS2441, AS2941 and AS4118.
11. Butterfly valves used for pump isolation shall not be installed on the suction side of fire water pumps
valves
Page 129 of 236
100-SP-PI-0001_Rev 3
Page 130 of 236
100-SP-PI-0001_Rev 3
10.1.16 Piping Class H1 – Mining Hose
Piping Class H1 Page 1 of 2
SERVICE: Slurry (SL); Tailings (TL) Process Water (PW)

CONDITION: Pressure: 700 kPa (g)
Not Applicable Class 150 Rubber Lined Mining Hose Above ground Nil
ITEM SIZE DESCRIPTION STANDARDS
HOSE DN 80-450
General Flexible heavy duty materials handling hose,

Reinforcement High tensile synthetic, incorporating a steel wire
helix
Lining 6 mm abrasion resistant natural rubber; 55-65 BS 6374 Part 5
Shore "A" hardness
Flanges DN 75-450 Preformed beaded (swivel or rotating) flange end ANSI/ASME B 16.5
with Class 150 galvanised steel backing ring
COUPLINGS DN 75-200 Cast iron; split bolt on flange fitting one end; ANSI/ASME B 16.5
integrated flange one end; drilled to Class 150,
FF;
DN 250-450 High strength cast iron integral moulded flanged ANSI/ASME B 16.5
ends; drilled to Class 150; FF;
GASKETS All Gasket Material – KLINGERlastic elastomers > ASME B 16.21

NBR - Nitrile
Thickness – 3.0mm
thread
DN15-50 - - - -
DN80-300 - - - -
DN350 and - - - -
above
Page 131 of 236
100-SP-PI-0001_Rev 3
REMARKS:
1. Minimum bend radius 8 x hose diameter
2. Hose Dimensions as per Manufacturers Schedule.
3. The hose shall be suitable for slurry applications, carrying particles of up to 5 mm at a maximum velocity of 5 metres per
second.
4. For DN 250-450, the rubber and fabric reinforcement of the hose body shall be extended over the full face of the flange.
5. Moulded in steel backing flanges shall be included on all integral flanges.
7. Cast iron couplings to be painted as detailed in this specification.
Page 132 of 236
100-SP-PI-0001_Rev 3
10.1.17 Piping Class H2 – High Pressure Hose
SERVICE: Gland Seal Water (GW)

DESIGN Temperature: 0 – 100ºC Pressure: 30 bar Max. Test Pressure: 50% above system pressure
CONDITION:

RATING
AS 4041 NA High Pressure Hose with Above ground Nil

Stainless Steel Fittings
ITEM SIZE DESCRIPTION STANDARDS
Hose DN 20-40 Parker 381-16, or approved equivalent SAE 100R1, SAE J1273
FITTINGS DN 15-40 As detailed below, or approved equivalents SAE 100R1, SAE J1273
Stainless Steel Construction
Hose End Fittings Hose Connection Fittings
Parker: Parkrimp (Crimp) Series 43 Hose Fittings Parker: Triple-Lok 37º Flare Tube Fittings
Description: Female JIC º - Swivel Description: CTX – Male Elbow

37º Flare (JIC) x NPTF
Size: Part Number: Size: Part Number:
DN15xDN20 JIC 10643-12-8C DN20 JICxDN25 NPTF 12-16 CTX-SS
DN20xDN25 JIC 10643-16-12C DN25 JICxDN25 NPTF 16-CTX-SS
DN25xDN25 JIC 10643-16-16C DN40 JICxDN40 NPTF 24-CTX-SS
DN40xDN40 JIC 10643-24-24C
Description: Male NPTF Pipe-Rigid Description: FTX - Male Connector

37º Flare (JIC) x NPTF
DN15xDN20 NPTF 10143-12-8C DN20 JICxDN15 NPTF 12-8 FTX-SS
DN20xDN20 NPTF 10143-12-12C DN20 JICxDN20 NPTF 12 FTX-SS
DN25xDN20 NPTF 10143-12-16C DN25 JICxDN20 NPTF 16-12 FTX-SS
DN25xDN25 NPTF 10143-16-16C DN25 JICxDN25 NPTF 16 FTX-SS
DN40xDN40 NPTF 10143-24-24C DN40 JICxDN40 NTPF 24 FTX-SS
Female JIC 37º - Swivel – F3MX - Male Connector

Description: Description:
90º Elbow – Short Drop 37º Flare (JIC) x BSPT
DN15xDN20 JIC 13943-12-8C DN20 JICxDN15 BSPT 12-8F3MX-SS
DN20xDN20 JIC 13943-12-12C DN20 JICxDN20 BSPT 12F3MX-SS
DN20xDN25 JIC 13943-16-12C DN25 JICxDN20 BSPT 16-12F3MX-SS
Page 133 of 236
100-SP-PI-0001_Rev 3
Description: JIC Union Tee

Size: Part Number:
DN20xDN20XDN20 12-JTX-SS
DN25xDN25xDN25 16-JTX-SS
DN40xDN40xDN40 24-JTX-SS
REMARKS:
1. All fittings to be Stainless Steel construction which must be specified in part number as detailed above
2. Alternative fitting sizes from corresponding Parker ranges as above may be used, or approved equivalents in all cases
4. Assembly as per manufacturers requirements
Page 134 of 236
100-SP-PI-0001_Rev 3
10.1.18 Piping Class H3 – General Service Hose
SERVICE: Instrument Air (IA) Plant Air (PA) Process Water (PW) Raw Water (RW)
DESIGN Temperature: 0 – 80ºC Pressure: 20 bar Max. Test Pressure: 50% above system pressure
CONDITION:

RATING
ISO 1307 NA Air & Water Hose Above ground Nil
AS 2554
ITEM SIZE DESCRIPTION
Hose DN 15 – 50 Dixon; A191 – Super Heavy Duty Air & Water Hose, as detailed below

Dixon; Double Bolt Claw Clamp – 2 off per hose assembly, unless otherwise specified
Hose Clamp DN 15 – 50
As detailed below for applicable hose size
Page 135 of 236
100-SP-PI-0001_Rev 3

Dixon; Hose End - Standard
FITTINGS DN 15 – 50 Hose End As detailed below for applicable hose size.
2 off per hose assembly unless otherwise specified.
Dixon; Male or Female NPT threaded fitting to suit hose and hose
end connection as required as detailed below.
Supply/Discharge
DN 15 – 50 Note: Below listed part numbers are for BSP threaded fittings only,
Connections
NPT thread shall be specified with corresponding correct
part numbers obtained from Dixon as required.
REMARKS:
1. Hose assemblies shall be as listed above or alternatives as approved by the Principal
3. Assembly as per manufacturers requirements
4. Fittings and hoses for air and water are not interchangeable.
5. All assemblies must be used with the appropriate clip to secure the joint.
Page 136 of 236
100-SP-PI-0001_Rev 3
10.1.19 Piping Class P1 – HDPE, PN 6.3
Piping Class P1 Page 1 of 2
SERVICE: Potable Water (PO) Raw Water (RW) Process Water (PW) Saline Water (SW)
Flocculent (FL) Oily Water (OW) Waste Water (WW)
DESIGN Temperature: 35°C
o
50 C
o
65 C
CONDITION:
Pressure: 500 kPa(g) 410 kPa(g) 330 kPa (g)
Test Pressure: 625 kPa (g) hydrostatic max at 35ºC
CODE FLANGE RATING MATERIAL Location CORROSION ALLOWANCE
AS 4041 PN6.3 HDPE (Polyethylene) Above ground Nil

AS 2566 PE100, PN 6.3
SDR = 26
White – co-extruded

PIPE DN 25-600 PE100; PN 6.3 (see remark 5) AS 4131; AS 4130
FITTINGS DN 25-75 Fabricated or moulded fittings PE100 AS 4131; AS 4129

PN6.3 or greater. Threaded or
compression fittings.
Fabricated or moulded fittings PE100
DN 90-600 PN6.3 or greater. BW.
BEND RADIUS DN 25-600 Bend radius shall be 2 x D (min),

unless otherwise specified on project
design drawings or approved by
Principal.
FLANGES DN 25-600 Stub ends; BW; c/w Class 150 AS 4131; AS 4129; ASTM A 105; ANSI/ASME B
galvanised carbon steel backing flange 16.5

Thickness – 3.0mm
coarse thread

CONNECTIONS Section 8.8.4
DN15-50 BA1, BF1, DP1, GA1 BF1, DP1 NR1 AV1

DN80-150 BA2, BF1, GA2, DP1 BF1, DP1 NR2 AV2
DN200-300 BF1, GA2 BF1 NR2 AV2
DN350-600 BF2, GA2 BF2 NR2, NR3 -
Page 137 of 236
100-SP-PI-0001_Rev 3
REMARKS:
valves
5. All above ground HDPE pipe shall be co-extruded with a white cover to reduce solar heating effect
Page 138 of 236
100-SP-PI-0001_Rev 3
Oily Water (OW) Waste Water (WW) Slurry (SL)
o
50 C
o
65 C
CONDITION:
Pressure: 550 kPa(g) 410kPa(g) 330kPa(g)
AS 4041 PN6.3 HDPE (Polyethylene) Below Ground Nil

AS 2566 PE100, PN 6.3 (Note 8)
SDR = 26

PIPE DN 25-600 PE100; PN 6.3 (Note 8) AS 4131; AS 4130

BEND RADIUS DN 25-600 Bend radius shall be 2 x D (min.),
Principal.

Thickness – 3.0mm
coarse thread

DN15-50 - - - -
DN80-150 GA3 - - -
DN200-300 GA3 - - -
DN350-600 GA3 - - -
Page 139 of 236
100-SP-PI-0001_Rev 3
REMARKS:
5. All below ground flange connections with galvanised steel backing rings and galvanised bolts shall be Denso Wrapped as per
Sections 8.1.20 to 8.1.21
8. Piping class may be used for above ground launder or drain type applications with atmospheric operating pressure and
revised pipe support spacing’s along with Victaulic Coupling Style 995, Plain End Piping System for HDPE Pipe (or approved
equivalent) to provide construction/maintenance joints only where specified on project design drawings, or with prior approval
by the Principal on an individual basis, with no exceptions. All above listed valves for this piping class shall not be used for
such applications.
Page 140 of 236
100-SP-PI-0001_Rev 3
10.1.21 Piping Class P3 – HDPE, PN8
Flocculent (FL) Oily Water (OW) Waste Water (WW)
o
50 C
o
65 C
CONDITION:
AS 4041 PN8 HDPE (Polyethylene) Above Ground Nil

AS 2566 PE100, PN 8.0
SDR = 21


PN8 or greater. Threaded or
DN 90-600 PN8 or greater. BW.
Principal.

Thickness – 3.0mm
coarse thread


DN80-150 BA2, BF1, GA2 BF1 NR2 AV2
DN350-600 BF2, GA2 BF2 NR2, NR3 -
Page 141 of 236
100-SP-PI-0001_Rev 3
REMARKS:
valves
Page 142 of 236
100-SP-PI-0001_Rev 3
10.1.22 Piping Class P4 –HDPE, PN8
Oily Water (OW) Waste Water (WW) Slurry (SL)
o
50 C
o
65 C
CONDITION:
AS 4041 PN8 HDPE (Polyethylene) Below Ground Nil

AS 2566 PE100, PN 8 (Note 8)
SDR = 21

PIPE DN 25-600 PE100; PN 8 (Note 8) AS 4131; AS 4130

Principal.

Thickness – 3.0mm
coarse thread

DN15-50 - - - -
DN80-150 GA3 - - -
DN200-300 GA3 - - -
DN350-600 GA3 - - -
Page 143 of 236
100-SP-PI-0001_Rev 3
REMARKS:
such applications.
Page 144 of 236
100-SP-PI-0001_Rev 3
SERVICE: Potable Water (PO) Raw Water (RW) Process Water (PW) Gland Seal Water (GW)
Saline Water (SW) Flocculent (FL) Oily Water (OW) Waste Water (WW)
o
50 C
o
65 C
CONDITION:
Test Pressure: 1,000 kPa (g) hydrostatic max at 35ºC
AS 4041 PN10 HDPE (Polyethylene) Above ground Nil

AS 2566 PE100, PN 10
SDR = 17

PIPE DN 25-600 PE100; PN 10 (see remark 5) AS 4131; AS 4130

Principal.

Thickness – 3.0mm
coarse thread


DN350-600 BF2, GA2 BF2 NR2, NR3 -
Page 145 of 236
100-SP-PI-0001_Rev 3
REMARKS:
valves
Page 146 of 236
100-SP-PI-0001_Rev 3
Saline Water (SW) Oily Water (OW) Waste Water (WW) Slurry (SL)
o
50 C
o
65 C
CONDITION:
AS 4041 PN10 HDPE (Polyethylene) Below Ground Nil

AS 2566 PE100, PN 10 (Note 8)
SDR = 17

PIPE DN 25-1200 PE100; PN 10 (Note 8) AS 4131; AS 4130

Principal.
FLANGES DN 25-1200 Stub ends; BW; c/w Class 150 AS 4131; AS 4129; ASTM A 105; ANSI 16.47
galvanised carbon steel backing flange Series A

Thickness – 3.0mm
coarse thread

DN15-50 - - - -
DN80-600 GA3 -
DN630-1200 GA3A - - -
Page 147 of 236
100-SP-PI-0001_Rev 3
REMARKS:
such applications.
Page 148 of 236
100-SP-PI-0001_Rev 3
Slurry (SL) Tailings (TL) Saline Water (SW) Oily Water (OW)
Waste Water (WW)
o
50 C
o
65 C
CONDITION:
Pressure: 1,000 kPa(g) 810kPa(g) 660kPa(g)
AS 4041 PN12.5 HDPE (Polyethylene) Above ground Nil

AS 2566 PE100, PN 12.5
SDR = 13.6


Principal.

Thickness – 3.0mm
coarse thread


DN350-600 BF2, GA2 BF2 NR2, NR3 -
Page 149 of 236
100-SP-PI-0001_Rev 3
REMARKS:
valves

Page 150 of 236
100-SP-PI-0001_Rev 3
Waste Water (WW)
o
50 C
o
65 C
CONDITION:
Max. Test Pressure: 1,362 kPa (g) hydrostatic max at 30ºC
AS 4041 PN12.5 HDPE (Polyethylene) Below Ground Nil

AS 2566 PE100, PN 12.5 (Note 8)
SDR = 13.6

PIPE DN 25-600 PE100; PN 12.5 (Note 8) AS 4131; AS 4130

DN 90-600 PN12.5 or greater. BW
Principal.

Thickness – 3.0mm
coarse thread

DN15-50 - - - -
DN80-150 GA3 - - -
DN200-300 GA3 - - -
DN350-600 GA3 - - -
Page 151 of 236
100-SP-PI-0001_Rev 3
REMARKS:
such applications.
Page 152 of 236
100-SP-PI-0001_Rev 3
Waste Water (WW)
DESIGN Temperature: 35°C 50 C
o o
65 C
CONDITION:
AS 4041 PN16 Polyethylene Pipe Above Nil

PE100 - PN 16 ground
AS 2566
SDR = 11

PIPE DN 25-600 PE100, PN16 (see remark 5) AS 4131; AS 4130
FITTINGS DN 25-75 Fabricated or moulded fittings PE100 PN16 AS 4131; AS 4129

or greater. Threaded or compression
fittings.
DN 90-600 Fabricated or moulded fittings PE100 PN16 AS 4131; AS 4129
or greater. BW
BEND RADIUS DN 25-600 Bend radius shall be 2 x D (min.), unless
FLANGES DN 25-600 Stub ends; BW; c/w Class 150 galvanised AS 4131; AS 4129; ASTM A 105; ANSI/ASME B
carbon steel backing flange 16.5

Thickness – 3.0mm
coarse thread

DN15-50 BA1, GA1 BA1 NR1 AV1

DN350-600 BF2, GA2 BF2 NR2, NR3 -
Page 153 of 236
100-SP-PI-0001_Rev 3
REMARKS:
1. Valves listed in the above Valve Table for this Piping Class are for general service use for the full pressure range of this Piping Class,
however all listed valves are not necessarily suitable for all listed fluid classes. Valves shall only be used on Fluid Class and duty
applications as approved in the individual Valve Data Sheets in Section 10.2.
2. Valves not listed in the above Valve Table for this Piping Class shall only be used with prior approval by the Principal on an individual
basis, or as designated on approved Project P&ID drawings. This includes instances where an individual pipe system’s absolute
maximum operating pressure will be lower than that specified for this Piping Class, thus allowing suitably lower pressure rated valves to
be used as listed in Section 10.2.
4. Valves of Class BF1 and BF2 shall only be installed between mating flanges and shall not be installed as end of line valves
Page 154 of 236
100-SP-PI-0001_Rev 3
Notes 4,5
Tailings (TL) Fire Water (FW) Saline Water (SW) Oily Water (OW)
Waste Water (WW)
o
50 C
o
65 C
CONDITION:
AS 4041 PN16 Polyethylene Pipe Below Ground Nil

AS 2566
PE100 - PN 16 (Note 10)
AS 2419
AS 2941 SDR = 11

PIPE DN 25-1200 PE100, PN16 (Note 10) AS 4131; AS 4130

DN 90-1200 Fabricated or moulded fittings PE100 AS 4131; AS 4129
PN16 or greater. BW
Principal.
FLANGES DN 25-1200 Stub ends; BW; c/w Class 150 galvanised AS 4131; AS 4129; ASTM A 105; ANSI/ASME
carbon steel backing flange B 16.5

Thickness – 3.0mm
coarse thread

DN15-50 - - - -
DN80-600 GA3 - - -
DN630-1200 GA3A - - -
Page 155 of 236
100-SP-PI-0001_Rev 3
REMARKS:
used for sprinkler systems, valves shall be in accordance with this specification to maximise site spares holdings.
including AS2118, AS 2419, AS2441, AS 2941 and AS4118.
6. Butterfly valves shall not be installed on the suction side of fire water pumps
such applications.
Page 156 of 236
100-SP-PI-0001_Rev 3
SERVICE: Potable Water (PO) Raw Water (RW) Process Water (PW) Slurry (SL)
Tailings (TL) Saline Water (SW) Oily Water (OW) Waste Water (WW)
DESIGN Temperature: 35°C 50 C
o o
65 C
CONDITION:
AS 4041 PN20 Polyethylene Pipe Above ground Nil

AS 2566 PE100 - PN 20
SDR = 9

PIPE DN 25 -400 PE100, PN20 (see remark 5) AS 4131; AS 4130

PN20 or greater. BW
Principal.
FLANGES DN 25-400 Stub ends; BW; c/w Class 150 AS 4131; AS 4129; ASTM A 105; ANSI 16.47

Thickness – 3.0mm
coarse thread


DN350-600 BF2, GA2 BF2 NR2, NR3 -
Page 157 of 236
100-SP-PI-0001_Rev 3
REMARKS:
valves
Page 158 of 236
100-SP-PI-0001_Rev 3
SERVICE: Potable Water (PO) Raw Water (RW) Process Water (PW) Slurry (SL)
Tailings (TL) Saline Water (SW) Oily Water (OW) Waste Water (WW)
o
50 C
o
65 C
CONDITION:
AS 4041 PN20 Polyethylene Pipe Below ground Nil

AS 2566 PE100 - PN 20
SDR = 9

PIPE DN 450 - PE100, PN20 AS 4131; AS 4130
1200
FITTINGS DN 450 - Fabricated or moulded fittings PE100 AS 4131; AS 4129

1200 PN16 or greater. BW
Principal.
DN 630-1200 Stub ends; BW; c/w Class 150 AS 4131; AS 4129; ASTM A 105; ANSI 16.47

Thickness – 3.0mm
coarse thread

DN 450-560 GA3
DN 630-1200 GA3A
Page 159 of 236
100-SP-PI-0001_Rev 3
REMARKS:
Piping Class, however all listed valves are not necessarily suitable for all listed fluid classes. Valves shall only be used
on Fluid Class and duty applications as approved in the individual Valve Data Sheets in Section 10.2.
2. Valves not listed in the above Valve Table for this Piping Class shall only be used with prior approval by the Principal on
an individual basis, or as designated on approved Project P&ID drawings. This includes instances where an individual
pipe system’s absolute maximum operating pressure will be lower than that specified for this Piping Class, thus allowing
suitably lower pressure rated valves to be used as listed in Section 10.2.
5. All below ground flange connections with galvanised steel backing rings and galvanised bolts shall be Denso wrapped
as per section 8.1.20 to 8.1.21
Page 160 of 236
100-SP-PI-0001_Rev 3
10.1.31 Piping Class R1 – Carbon Steel, Rubber Lined, Std. Wt.
Piping Class R1 Page 1 of 2

CONDITION:
Pressure: 1000 kPa (g)
Test Pressure: 1,500 kPa (g) hydrostatic (Note 7)
AS 4041 Class 150 Carbon Steel – 6mm Natural Above ground Nil
Rubber - Lined
PIPE DN 80-250 SMLS; Sch. std wt; BW API 5L GR B; ANSI/ASME B 36.10 & B 16.25
DN 300-600 ERW Std. Wt; BW API 5L GR B; ANSI/ASME B 36.10 & B 16.25
FITTINGS
Elbows (Note 6) DN 80-600 SMLS; Sch. Std. Wt.; LR, BW, ASTM A 234 GR WPB; ANSI/ASME B 16.9
Fabricated with FLGD ends
Bends DN80-250 Fabricated 3D, Std. Wt., SMLS, FLGD, API 5L GR B; ANSI/ASME B 36.10
DN 300-600 Fabricated 3D, Std. Wt., ERW, FLGD, API 5L GR B; ANSI/ASME B 36.10
Tees Main Run Fabricated from Pipe material, FLGD. API 5L GR B; ANSI/ASME B 36.10
DN80-600 Reinforced where required by AS4041.
Branch
DN50-80
Laterals: 45° to DN 80-600 Fabricated from Pipe material, FLGD. API 5L GR B; ANSI/ASME B 36.10
60° Reinforced where required by AS4041.
Rubber Lined DN 80-600 Fabricated from Pipe material, FLGD API 5L GR B; ANSI/ASME B 36.10
Walking Stick
Reducers DN 50-600 Fabricated out of CS plate material in AS4041.

accordance with AS4041,, FLGD
LINING DN 80-600 6mm thick, 95% natural rubber - Section 8.9 of this Specification
Linatex
FLANGES DN 80-600 Class 150; FF, SO or WN ASTM A 105, ANSI/ASME B 16.5
GASKETS All 1.5mm PTFE ASME B 16.21
coarse thread
TESTING All Rubber lining to be spark tested; Piping BS 6374, Part 5; AS 4041
to be hydrostatic tested
Miscella
Valves Isolation Throttling Non – Return Flushing
neous
DN 80-200 KG1 - NR6 25 BA1, 50 BA5 AV3
DN 250-600 KG2, KG3 (Note - NR6 AV3
8)
Page 161 of 236
100-SP-PI-0001_Rev 3
REMARKS:
Piping Class (except KG1 & KG2, limited to 700kPa (g)), however all listed valves are not necessarily suitable for all listed
fluid classes. Valves shall only be used on Fluid Class and duty applications as approved in the individual Valve Data Sheets
in Section 10.2.
4. Straight runs of pipe shall be fabricated in standard flanged lengths of 6,0m face to face.
6. Elbows shall only be used with approval of Principal Piping Engineer
7. For hydro testing, test pressures shall be taken from line list. Valves shall be isolated from pressure testing.
8. KG3 shall be used for isolation where operating pressures exceed 700 kPa (g).
9. All process flow carrying lines shall be minimum DN80. DN50 branches may be used for drain, vent, flushing and instrument
connections. In such cases DN50 pipe and flange material shall be as specified above for DN80.
10. Tails on drains, complying with piping material class R1, may be unlined downstream of the main process flow isolation valve.
Page 162 of 236
100-SP-PI-0001_Rev 3
10.1.32 Piping Class R2 – Carbon Steel, Rubber Lined, Sch. 80

CONDITION:
AS 4041 Class 300 Carbon Steel – 6mm Natural Above ground Nil
Rubber Lined, Sch. 80
PIPE DN 80-350 SMLS; Sch. 80; BE API 5L GR B; ANSI/ASME B 36.10 & B 16.25
FITTINGS
Elbows DN 80-350 SMLS; Sch. 80; BE API 5L GR B; ANSI/ASME B 36.10 & B 16.25
Tees DN 80-350 SMLS; Sch. 80; BW API 5L GR B; ANSI/ASME B 16.9
Reducers DN 80-350 SMLS; Sch. 80; BW ASTM A 234 GR WPB; ANSI/ASME B 16.9
LINING DN 80-350 6mm thick, 95% natural rubber - Section 8.9 of this Specification
Linatex
FLANGES DN 80-350 Class 300; FF, SO or WN ANSI/ASME B 16.5
GASKETS All 1.5mm PTFE ASME B 16.21
coarse thread
TESTING All Rubber lining to be spark tested; Piping BS 6374, Part 5; AS 4041
to be hydrostatic tested

DN80-350 - - NR6 AV3

Page 163 of 236
100-SP-PI-0001_Rev 3
REMARKS:
4. Straight runs of pipe shall be fabricated in standard flanged lengths of 6,0m face to face.
Page 164 of 236
100-SP-PI-0001_Rev 3
10.1.33 Piping Class R3 – Carbon Steel, Rubber Lined, (St. Wt. Victaulic)

CONDITION:
Pressure: 700 kPa (g)
AS 4041 Class 150 Carbon Steel St. Wt. – 6mm Above ground Nil
Natural Rubber Lined
Cut Groove Victaulic System
PIPE DN 80-450 ERW, St. Wt., CUT groove carbon steel pipe API 5L GR B; ANSI/ASME B
Victaulic IPS coupling CUT groove profile - as below 36.10
LINING DN 80-450 6mm thick, 95% natural rubber - Linatex Section 8.9 of this
MATERIAL & Specification
GROOVING
DETAILS DN80-450 Victaulic IPS pipe
system rubber lining
and cut groove details
shown below as per
Victaulic Publication
25.03
COUPLINGS DN 80-450 Victaulic IPS Style 07 Rigid or Style 77 Std. Flexible ASTM A 536, ASTM F1476
Couplings - Painted
FITTINGS DN 80-450 Victaulic IPS fittings ANSI/ASME B 16.5,
ASTM F1476
ELBOW RADIUS DN 80-450 Elbow shall be long radius, unless otherwise specified on ANSI/ASME B 16.9
project design drawings or approved by Principal.
BENDS DN80-450 Piping Class H1 Section 10.1.14 of this Spec.
FLANGES DN 80-450 Victaulic IPS flanged adaptor nipple, No. 45F, ANSI Class ANSI/ASME B 16.5
150, FF
DN 80-450 Victaulic IPS flange adaptor, Style 741, ANSI Class 150 ANSI/ASME B 16.5
GASKETS Couplings “Flush Seal” style Victaulic Grade “E” EPDM coupling ANSI/NSF 61
gaskets for IPS couplings
Flange 1.5mm PTFE – between mating rubber to rubber, or rubber
Connections to steel
Gasket Material – KLINGERsil C6327 ASME B 16.21
Thickness – 1.5mm
Gasket Style – IBC Ring gasket, or approved equivalent
Page 165 of 236
100-SP-PI-0001_Rev 3

All flange Stud bolts; continuous thread; unified coarse thread ASTM A 193 GR B7;
connections ANSI/ASME B 1.1
Two (2) heavy hexagonal nuts per stud bolt; unified ASTM A 194 GR 2H;
coarse thread ANSI/ASME B 1.1
DN80-450 DP1, KG1, KG2, KG3, - NR6 -

RD1
REMARKS:
Page 166 of 236
100-SP-PI-0001_Rev 3
10.1.34 Piping Class S1 – Pressfit Stainless Steel
Piping Class S1 Page 1 of 2
SERVICE: Potable Water (PO) Chilled Water (CW) Gland Seal Water (GW) Process Water (PW)
Plant Air (PA) Instrument Air (IA) Raw Water (RW) Waste Water (WW)
Note: Refer remark 11, 12 & 13.

CONDITION:
Pressure: 1,600 kPa (g) @ 90ºC to ANSI Class 150 (Grade E “O” rings)
Test Pressure: 2,400 kPa (g)
Victaulic Vic-Press system

in 316 Stainless Steel
AS 4041 Class 150 Above ground Nil
Ibex Tubepress system in
316L Stainless Steel
PIPE DN 15-50 Vic-Press: Sch. 10S pipe, plain ends Vic-Press: ASTM A-312 TP316/316L, ASME
B36.19M
OR
Tubepress: Plain end “Tubepress”
tubes Tubepress: Tubepress/ Sanha 316L SS / 1.4404
Bright Annealed Solution Heat Treated Tubes
according to EN10312 & EN10088
FITTINGS DN 15-50 Vic-Press Sch. 10S couplings and All: NPT (when threaded)
fittings
Vic-Press: ASTM A-312 TP316S/S.
OR
Tubepress fittings Tubepress: 316L SS / 1.4404 Bright Annealed
Solution Heat Treated according to EN10312 &
EN10088), 316SS / 1.4408 to EN10283.
FLANGES DN 15-50 Vic-Press Style 575 Flange Adaptor All: ANSI/ASME B 16.5, class 150, RF
(FF by exception OR Vic-Press: TP316S/S
per 8.2.2) Pressfit 316 S/S Style 566 Van Stone Tubepress: 316L SS / 1.4404 Bright Annealed
Flange Adaptor Solution Heat Treated according to EN10312 &
EN10088), 316SS / 1.4408 to EN10283.
Tubepress flange adapter fittings
INSULATED DN 15-50  Insulated flange bolting kit

CONNECTIONS  Style 47-GT or Style 47-TT Victaulic
(Dissimilar metals Dielectric Waterway Fitting
pipe system
connection)
Fitting O-Rings Vic-Press: O-rings - Grade "H" Vic-Press: ANSI/NSF 61 Annex G

Hydrogenated Nitrile Butadiene
Rubber (HNBR)
Tubepress: Series 9000 EPDM (colour
black), Series 18000 FKM Flurocarbon
(Viton) (colour red)
Gaskets All KLINGERsil C6327 ASME B 16.21

Thickness – 1.5mm
Gasket Style – IBC Ring gasket.
Page 167 of 236
100-SP-PI-0001_Rev 3
stud bolts; continuous thread; unified

ASTM A 193 GR B8 Class 2; ANSI/ASME B 1.1
coarse thread – S/S
BOLTING All
two (2) heavy hexagonal nuts per stud
ASTM A 194 GR 8; ANSI/ASME B 1.1
bolt; unified coarse thread – S/S
Valves Isolation Throttling Non - Return Miscellaneous
DN15-50 (note 13) BA1, BA4, BF1, GA1, BF1 NR1, NR2 AV1
BA6
REMARKS:
7. Insulated Pipe Supports shall be used for all Class S1 pipe work with insulated flange connections to be used when
connecting to dissimilar conductive materials such as steel pipes, tanks and pumps.
11. This piping system shall not be used at the Port in untreated water (GW, PW, RW, WW, OW, SW) due to water quality
/ sulphate reducing bacteria (SRB) problems.
12. When used in untreated water outside of the Port, the water quality shall be verified to be free of sulphur reducing
bacteria (SRB).
13. Where no significant vibration exists and reciprocating pumps are NOT used, this piping system may be used in hydrocarbon
service with approval of the Principal. In such cases, BA5, GA5, GA7, NR5 or Principal approved alternative valves shall be
used as appropriate for the fluid service.
14. Valves shall be selected and specified to suit the designed operating conditions.
15. When hoses or other piping systems are connected to Class S1 piping adequate support shall be provided.
Page 168 of 236
100-SP-PI-0001_Rev 3
10.1.35 Piping Class S2 – 316 Stainless Steel
SERVICE: Potable Water (PO) Raw Water (RW) Gland Water (GW) Process Water (PW)

CONDITION:
AS 4041
Class 150 316 Stainless Steel Above ground 2.0 mm
AS 3500
PIPE DN 15-50 SMLS; Sch. 80S; NPT ASTM A 312 GR TP316L;

ANSI/ASME B 36.19
DN 80-400 ERW; Sch. 40S; BE ASTM A 312 GR TP316L;

ANSI/ASME B 36.19 & B 16.25
FITTINGS DN 15-50 forged; Class 3000; NPT ASTM A 182 GR F316L; ANSI B 16.11
DN 80-400 Welded; Sch. 40S; BW ASTM A 403 GR WP316LW; ANSI/ASME B 16.9
'OLETS DN 15-50 forged; Class 3000; NPT ASTM A 182 GR F316L
FLANGES DN 15-400 Class 150; RF, SO or WN ASTM A 182 GR F316L; ANSI/ASME B 16.5
(FF by exception per
8.2.2)
ORIFICE FLANGES DN 25-400 WN; Class 300; RF ASTM A 182 GR F316L; ANSI/ASME B 16.36

Thickness – 1.5mm
BOLTING All stud bolts; continuous thread; unified ASTM A 193 GR B8 Class 2; ANSI/ASME B 1.1
coarse thread – S/S
two (2) heavy hexagonal nuts per stud ASTM A 194 GR 8; ANSI/ASME B 1.1
bolt; unified coarse thread – S/S

Valves Isolation Throttling Non - Return Miscellaneous

DN350-400 BF2, GA2 BF2 NR2, NR3 -
Page 169 of 236
100-SP-PI-0001_Rev 3
REMARKS:
valves
5. All welds on stainless steel pipe work shall be internally and externally treated with acid pickling and passivation, unless
otherwise approved by the Principal
6. Insulated Pipe Supports shall be used for all Class S2 pipe work, with insulated flange connections to be used when
connecting to dissimilar conductive materials such as steel pipes, tanks and pumps.
Page 170 of 236
100-SP-PI-0001_Rev 3
10.1.36 Piping Class U1 ‐ Polyurethane Lined Carbon Steel Piping, Std. Wt.
Page 1 of
Piping Class U1 2
Neutral Pulp (NP), Acid Pulp (AP), Tailings (TL), Slurry (SL)
SERVICE:
Temperature: 0 - 90°C
DESIGN Pressure: 700 kPa (g)

CONDITION:
Test Pressure: 1050 kPa (g) hydrostatic
CORROSION
CODE FLANGE RATING MATERIAL
ALLOWANCE
AS 4041 Class 150 FF Carbon Steel Polyurethane Lined Nil
DN 50-150 ERW, Std Wt, flanged API 5L GR B, ANSI/ASME B36.10

PIPE
DN 200-750 ERW, Sch 20
FITTINGS
SMLS, Sch same as pipe,
DN 50-150 API 5L GR B, ANSI/ASME B16.9
flanged
Elbows
Welded, Sch same as pipe,
flanged
flanged
Tees
flanged
flanged
Reducers
flanged
MDI polyurethane, 88-92
Lining (Note
DN 50-750 Shore A hardness, ether
1)
material
DN 50-600 Class 150 FF ASTM A 105, ANSI/ASME B 16.5

FLANGES
DN 600-750 Class 150 FF ASTM A 105, MSS SP-44
ORIFICE
DN
FLANGES
GASKETS All 1.5mm PTFE FF

Page 171 of 236
100-SP-PI-0001_Rev 3
Piping Class U1 Page 2 of 2
Stud bolts; continuous

ASTM A 193 GR B7; ANSI/ASME B1.1
thread; unified coarse
ASTM A 193 GR B8;C1.2
thread
BOLTING All
Two (2) heavy hexagonal
ASTM A 194 GR 2H; ANSI/ASME B1.1
nuts per stud bolt; unified
ASTM A 194 GR 8
coarse thread
See Branch Connection

BRANCH
All Table in Section 8.10.3
CONNECTIONS
Table 27
Non –
Valves Isolation Throttling
Return
Miscellaneous
DN50-750 KG1
Notes:
1. Lining must be polyurethane MDI ether material with the following thicknesses:
DN150 – 8mm
DN200 – 10mm
DN250 to DN400 – 12mm
DN450 and above – 16mm
2. PH must be within the range of 1.5 to 13
3. The impingement angle for the polyurethane must be less than 60 degrees.
4. Carbon steel spool must be grit blasted to AS2.5 and inspected for removal of grease, oils and rust, freshly blasted
surfaces may be washed down with MEK (Methyl Ethyl Ketone). Within 2 hours of blasting the primer and bonding agent
must be applied.
5. Carbon steel spools shall have one coat of chemloc 219 barrier coat applied and within 48 hours shall have a coat of
chemloc 213 applied.
6. Carbon steel spools shall be rotationally cast, spools and fittings shall be cast with mandrills.
7. Carbon steel pipes shall be heated to 105°C prior to the application of the lining and shall have a minimum post cure
time of 16 hours at 100°C.
8. The polyurethane shall be tested by a Durometer and shall achieve its hardness within 24 hours to ensure the ratio of
polymer and curative are correct.
9. Polyurethane processor to produce daily batch samples of polyurethane and record batch numbers.
10. Polyurethane processing shall be automatic machine processing with recirculating head and mass flow mater to
ensure ratios of polymer and curative are correct. Hand mixing and use of fillers is strictly prohibited.
11. Linings shall be continuous and without seams. Flange gaskets are integral to the lining and shall extend over the
flange faces to the inside of bolt holes.
12. Linings shall be sparked tested to ensure an absence of porosity and in all applications where the PH us below 3,
spark testing is mandatory.
Page 172 of 236
100-SP-PI-0001_Rev 3
10.1.37 Piping Class W1 – UPVC (Pressure)
Piping Class W1 Page 1 of 2
SERVICE: Oily Water (OW) Saline Water (SW) Waste Water (WW) Sewage (SE)
DESIGN Temperature: 20 30 40 50 60 °C
CONDITION:
Pressure: 1,200 960 720 480 240 kPa (g)
Test Pressure: 1,560 kPa (g) hydrostatic at 20ºC
AS 4041 Class 150 Unplasticised Polyvinyl Chloride Above or Below Nil

AS 2032 (UPVC) PN12 ground
PIPE DN 15-300 UPVC pressure pipe; solvent weld joint AS 1477

ends; Class 12
FITTINGS DN 15-300 UPVC pressure fittings; solvent weld AS 1477

joint ends; Class 12 or Class 18
SOLVENT All To pipe manufacturers

recommendations
FLANGES DN 15-40 UPVC solvent welded; FF; drilled to AS 1477; ANSI/ASME B 16.5
Class 150
DN 50-300 UPVC solvent welded; FF; c/w 150 lb AS 1477; ASTM A 105; ANSI/ASME B 16.5
galvanised carbon steel backing flange
BLIND FLANGES DN 15-300 Class 150; FF; GALV ASTM A 105; ANSI/ASME B 16.5

Thickness – 3.0mm
coarse thread
BRANCH All Refer to manufacturer's catalogue.

CONNECTIONS
DN15-50 BA1, BF1, GA1 BF1 NR1 -

DN80-150 BA2, BF1, GA2, GA3 BF1 NR2 -
DN200-300 BF1, GA2, GA3 BF1 NR2 -
Page 173 of 236
100-SP-PI-0001_Rev 3
REMARKS:
1. Piping materials and fittings for all Pressure UPVC applications shall comply with AS 2032, AS 1477 and standards referenced
therein. Detailed design is the responsibility of the installation Contractor. Installation and testing shall comply with AS
2032. The complete installation shall comply with applicable statutory regulations including Plumbing Code of Australia, and
Water Service Licensing Regulations (2000) where applicable.
individual basis, or as designated on approved Project P&ID drawings. This includes instances where an individual pipe system’s
absolute maximum operating pressure will be lower than that specified for this Piping Class, thus allowing suitably lower pressure
rated valves to be used as listed in Section 10.2.
Page 174 of 236
100-SP-PI-0001_Rev 3
10.1.38 Piping Class W2 – UPVC (DWV)
SERVICE: Sewage (SE), Waste Water (WW)
DESIGN Temperature: Ambient

CONDITION:
Pressure: Atmospheric
Test Pressure: (a) Above ground: Static head of 3 metres above highest point in line.
(b) Below ground: Static head of 1 metre above highest point in line.
AS 2032 Not Applicable Unplasticised Polyvinyl Below ground Nil

Chloride (UPVC)
AS 3500.2
DWV – Drain, Waste, Vent
General 1. Detailed design of Piping Class W2 systems is the responsibility of the installation Contractor
2. Installation and testing shall comply with AS 3500.2
3. The complete installation shall comply with applicable statutory regulations including Plumbing Code of
Australia, and Water Service Licensing Regulations (2000).
4. Piping materials and fittings for all sewer and waste drainage shall be done in UPVC and shall comply with
AS 3500.2:2003 and standards referenced therein.
5. All below ground flange connections with galvanised steel backing rings and galvanised bolts shall be
Denso Wrapped as per Sections 8.1.20 to 8.1.21
6. Gaskets shall be:
Gasket Material – KLINGERlastic elastomers > NBR - Nitrile
Thickness – 3.0mm
Page 175 of 236
100-SP-PI-0001_Rev 3
10.2 Valve Data Sheets
10.2.1 Ball Valves (Data Sheet 1 of 5)
BALL VALVES
Valve Class BA1 BA2
Max Working Pressure 4,800kPa @ 100ºC 1,600kPa @ 80ºC
Fluid Class PO, RW, PW, GW, PA, IA, OW, FW, PO, RW, PW, GW, PA, IA, OW, FW,
WW, SW, CW, EC, WC WW, SW, EC, WC
Purpose Isolation on/off Isolation on/off
Type Ball Ball
Size DN8 to DN50 DN50 to DN200
Construction Full bore Full bore
Max Operating Temp 100ºC 80ºC
Ends NPT Female ANSI, Class 150 RF Flanged
Body Stainless steel ASTM A216 WCB
Ball Stainless Steel Stainless Steel
Stem Stainless Steel Stainless Steel
Stem Packing PTFE PTFE or Flexible Graphite
Seat PTFE PTFE
Manufacturer Tyco – Utility ball valve Flowserve Worcester
(or equal) F150 – economical three piece Series F819
Or approved equivalent Or approved equivalent
Pneumatic Operator N/A Optional
Manual Operator Lever – standard supply Lever – standard supply, gear operated
DN150-200
Note:  Standard manual operator to be  Standard manual operator to be
lockable and have visual indication of lockable and have visual indication of
ball location (valve state). ball location (valve state).
 Proximity switch mounting plates to be
available as option.
Page 176 of 236
100-SP-PI-0001_Rev 3
BALL VALVES
Valve Class BA3 BA4
Fluid Class PO, RW, PW, GW, OW, FW, WW PA, IA
Purpose Isolation On/off Isolation On/off
Type Ball Three-Way ball
Construction Full bore, two-piece “T” Port, Flow Plan G
Ends Victaulic grooved NPT Female
Body Ductile iron Stainless steel
Ball Stainless steel Stainless steel
Stem Stainless steel Stainless steel
Stem Packing Fluroelastomer PTFE
Seat TFE RPTFE
Manufacturer Victaulic, Series 726, Vic-ball valve Tyco – Utility ball valve
(or equal) Or approved equivalent F138 – Three way multi-port ball valve
Pneumatic Operator Optional N/A
Manual Operator Lever – standard supply Lever – standard supply
Note:  Standard manual operator to be  Valve is used as a self bleeding valve
lockable and have visual indication of on compressed air dropper assemblies
ball location (valve state). to vent down stream pressure when
 Proximity switch mounting plates to be turned off.
available as option.  T-Port flow plan as below

Page 177 of 236
100-SP-PI-0001_Rev 3
BALL VALVES
Valve Class BA5 BA6
Fluid Class DO, RW*, PW*, EO, GO, GRL, HO, PO, PA, IA
TO, WO
Type Ball Ball
Construction Full bore 3 Piece, Full bore
Ends ANSI, Class 150 RF Flanged Plain ends - Pressfit
Body Carbon Steel Stainless steel
Ball 316 Stainless Steel Stainless Steel
Stem 316 Stainless Steel Stainless Steel
Stem Packing Flexible Graphite
Seat RPTFE PTFE
Manufacturer Tyco R721 Victaulic, Vic-Press 316 Stainless Steel Ball
(or equal) Or approved equivalent Valve: Series 569
Pneumatic Operator Optional N/A

Manual Operator Lever – standard supply Lever – standard supply
Note:  Standard manual operator to be  Standard manual operator to be lockable
lockable and have visual and have visual indication of ball location
indication of ball location (valve (valve state).
state).
 Proximity switch mounting plates
to be available as option.
 Valve shall be regulatory
approved and/or compliant for
use in DO duty
 Valve shall be of the fire safe and
anti static type to API 607 ED4 or
BS6755 Part 2
 * For flushing slurry lines only
Page 178 of 236
100-SP-PI-0001_Rev 3
BALL VALVES
Valve Class BA7
Max Working Pressure 4000kPa @ 80ºC
Fluid Class DO
Purpose Isolation on/off
Type Full bore ball valve
Size DN15 to DN300
Construction Full bore
Max Operating Temp 80ºC
Ends ANSI, Class 300 RF Flanged
Body Carbon Steel
Ball Stainless steel 316
Stem Austenitic Stainless Steel
Seat R-PTFE
Manufacturer Crane ball valve:
(or equal) DN15-100: Cat # KF943
DN65-300: Cat # 90FSTEFS300
Pneumatic Operator Optional
Manual Operator DN15-100: Lever
DN125-300: Gear operated
Note:  Standard manual operator to be lockable and have visual
indication of ball location (valve state).
 Proximity switch mounting plates to be available as option.
 Valve shall be regulatory approved and/or compliant for use in
DO duty
 Valve shall be of the fire safe and anti-static type
Page 179 of 236
100-SP-PI-0001_Rev 3
BALL VALVES
Valve Class BA8 BA9
Design Standard MSS SP-110, ASME B16.34, API 607 API 6D, API 607, ASME B16.34
Max Working Pressure 1600 kPa @ 100ºC 1,600kPa @ 80ºC
Fluid Class EO ,TO, GO, HO, GRL, WO EO ,TO, GO, HO, GRL, WO
Type Ball Valve Ball Valve
Construction Full bore, three-piece body Reduced bore, Single piece body
Rating 1600 kPa @ 100ºC (minimum) Class 150

Ends Socket Weld to ASME B16.34 Flanged, RF ASME, B16.5
Body ASTM A351 Gr CF8M Carbon Steel
Ball ASTM A351 Gr CF8M 316 Stainless Steel
Stem 316 Stainless steel 316 Stainless Steel
Seat Reinforced PTFE PTFE
Manufacturer Tyco (Richards) or approved equal Tyco (Richards) or approved equal

(or equal) R183, Padlockable or approved equal R711, Padlockable or approved equal
Operator Lever, Clockwise Close Lever, Clockwise Close
Note:  Maximum design temperature of Lockable handle, blow-out proof stem,

100oC is for air systems only. fire safe, anti-static
Other services except diesel
have a maximum design
o
temperature of 80 C.
 Lockable handle, blow-out proof
stem, fire safe.
Page 180 of 236
100-SP-PI-0001_Rev 3
10.2.6 Butterfly Valves (Data sheet 1 of 2)
BUTTERFLY VALVES – BF1 & BF2 (Page 1 of 2)

Valve Class BF1 BF2
Max Working 1,600kPa @ 80ºC 1,600kPa @ 80ºC
Pressure
Fluid Classes PO, RW, PW, GW, CW, WW, SW, FW, EC, PO, RW, PW, GW, SW, WW, EC, WC
WC
Purpose Isolation (on/off) or Throttling Isolation (on/off) or Throttling
Type Butterfly – Lugged Body Butterfly – Lugged Body
Size DN50 - DN300 DN350 – DN1200
Max Op. Temp 80ºC 80ºC
Ends Lugged body to suit ANSI Class 150 FF Lugged body to suit ANSI Class 150 FF flanges
flanges
Body Ductile Iron Ductile Iron
Disc S/Steel 316 Ductile Iron
Stem Stainless Steel 316 Stainless Steel 431
Seat/Seals Standard Seat Superseat
Buna N Buna N
Manufacturer Keystone – F612 DN350 - DN600: Keystone – F612
(or equal) Or approved equivalent. DN650 – 1200: Keystone – F631
Or approved equivalent.
Operator
Options:
Manual Sizes DN50 -DN150 - Lever Geared operator
Operator Sizes DN200 to DN300 – Geared operator
Pneumatic Optional - As detailed below, unless Optional - As detailed below, unless specified
Operator – specified otherwise on a specific instrument otherwise on a specific instrument data sheet.
“On/Off” data sheet.
Service
Note:  Shall not be installed as end of line devise  Shall not be installed as end of line devise
 Mating flanges for butterfly valves shall be  Mating flanges for butterfly valves shall be of
of the Weld Neck style only the Weld Neck style only
 Manual operator to be lockable  All valve operators shall have visual indication
 All valve operators shall have visual valve state.
indication of valve state.  Proximity switch mounting plates to be
 Proximity switch mounting plates to be available as option for manual valves.
available as option for manual valves.
Page 181 of 236
100-SP-PI-0001_Rev 3
BUTTERFLY VALVES – BF1 & BF2 (Page 2 of 2)

Pneumatic Operators, “On/Off” Service
Valve Class: BF1
Valve Valve Actuator Position Tyco Actuator Solenoid Valve Position Monitoring
Size Torque Type Indicator Actuator Torque Model (Note 7)
(Nm) Model (Nm) (Note 5&6)
(Note 1) (Note 2&3) (Note 4)
DN50 15 Dbl Act Yes F79U- 37 Asco - Product Tyco F792 Switchbox
003DA code: LP Series
DN80 36 Dbl Act Yes F79U- 70 VMG551B401MO EPD Descript:
006DA 24DC F792 LSB LP WP
2SPDT 20-260VAC
DN100 51 Dbl Act Yes F79U- 70
006DA
3/2, 5/2 NAMUR Part No: 422987
single solenoid
valve, ¼” port, 2-
IP67 rated
10bar, aluminium
012DA
body, manual
DN200 235 Dbl Act Yes F79U- 272 operator, epoxy
painted explosion
024DA
protected enclosure,
DN250 403 Dbl Act Yes F79U- 787 IP67, 24DC
065DA
065DA
Valve Class: BF2
Valve Valve Actuator Position Tyco Actuator Solenoid Valve Position Monitoring
Size Torque Type Indicator Actuator Torque Model (Note 7)
(Nm) Model (Nm) (Note 5&6)
(Note 1) (Note 2&3) (Note 4)
DN350 1053 Dbl Act Yes F79U- 2054 SMC - Model: Tyco F792 Switchbox
180DA VFA5120-03 LP Series
5 Port Air Operated EPD Descript:
DN400 1474 Dbl Act Yes F79U- 2054 Valve
180DA F792 LSB LP WP
Asco - Product 2SPDT 20-260VAC
1992 Dbl Act Yes F79U- 2054 Code:
DN450 Part No: 422987
180DA WPG327B001MO
IP67 rated
24DC
DN500 2615 Dbl Act Yes AM20DA 5255 3/2 single solenoid
valve, ¼” BSP port,
Brass body, manual
DN600 4216 Dbl Act Yes AM20DA 5255 operator, epoxy
painted steel
enclosure, IP67, 24DC
 Asco solenoid valve
to provide pilot air
to 5 port SMC valve
Notes: 1. Valve torque is from manufacturers data for full pressure range differential (16 bar).
2. Shall be Tyco Figure 79U type actuators, size as per above listed Tyco Actuator Number for corresponding butterfly
valve size. Or approved equivalent.
3. Pneumatic control solenoid valve arrangements shall be as listed above for corresponding butterfly valve size. Or
approved equivalent.
4. Valve actuator fitted only where detailed on Project P&ID drawings and associated Valve Lists.
5. Actuator torque is at 550kPa compressed air pressure with no change in required actuator if at 600kPa.
6. Solenoid valve, and air operated valve where fitted, shall be factory mounted directly to each actuator and hard piped
in stainless steel tubing.
7. Failure position of valve on loss of power only, (not loss of compressed air) to be as per Project P&ID drawings and
associated Valve Lists, unless otherwise specified.
8. Position Monitoring of valves shall be fitted only where detailed on Project P&ID drawings & associated Valve Lists.
9. Each actuated valve is to be shipped from factory with the FMG valve tag number clearly identified via a durable tag
attached to the valve and displayed on packaging.
Page 182 of 236
100-SP-PI-0001_Rev 3
10.2.7 Butterfly Valves (Data Sheet 2 of 2)
BUTTERFLY VALVES
Valve Class BF3 BF4
Max Working 2,065 kPa @ 110ºC 2065 kPa @ 110ºC
Pressure
Fluid Classes PO, RW, PW, GW, SW, WW, FW, OW PO, RW, PW, GW, SW, WW, FW, OW
Purpose Isolation (on/off) or Throttling Isolation (on/off) or Throttling
Type Butterfly – Grooved Butterfly – Grooved
Size DN80 – DN300 DN350 – DN600
Max Op. Temp 110ºC 110ºC
Ends Victaulic grooved Victaulic grooved
Body Ductile iron Ductile iron
Disc Stainless steel Stainless steel
Seat/Seals Nitrile Nitrile
Manufacturer Victaulic, MasterSeal, Vic – 300. Victaulic, Series 706.
(or equal) Or approved equivalent Or approved equivalent
Manual Operator Sizes DN50 -DN150 - Lever Geared Operator
For sizes DN200mm to DN300 – Geared
operator
Pneumatic Optional – to be approved on case basis by Optional – to be approved on case basis by
Operator Principal Principal
Note:  Butterfly valves shall not be used for end of  Butterfly valves shall not be used for end of
line service line service
 Standard manual operator to be lockable  Standard manual operator to be lockable
 All valve operators shall have visual  All valve operators shall have visual
indication of disc location (valve state). indication of disc location (valve state).
 Proximity switch mounting plates to be  Proximity switch mounting plates to be
available as option. available as option.
Page 183 of 236
100-SP-PI-0001_Rev 3
10.2.8 Diaphragm Valves
DIAPHRAGM VALVES
Valve Class DP1
Max Working Pressure Valve Size Pressure @ 55ºC
DN15 – DN100 1,000kPa
DN150 600kPa
DN200 – DN300 350kPa
DN350 150kPa
Fluid Classes PW, SL, TL, FL, OW, SW, RW
Purpose Isolation (on/off) or Throttling
Type Diaphragm – Straight through type
Size 15mm to 350mm
Ends ANSI Class 125 flanges
Body Cast iron
Body Lining HT – Polychloroprene, sulphur cured, black reinforced (Neoprene)
Spindle Carbon steel
Diaphragm HT – Polychloroprene, sulphur cured, black reinforced (Neoprene)
Manufacturer Saunders, KB type diaphragm Valve
(or equal) Or approved equivalent.
Operator Hand wheel
Note:  All valve operators shall have visual indication of valve state.
 Proximity switch mounting plates to be available as option.
Page 184 of 236
100-SP-PI-0001_Rev 3
10.2.9 Gate Valves (Data sheet 1 of 5)
GATE VALVES
Valve Class GA1 GA2
Max Working 1600kPa @ 80ºC 1600kPa @ 95ºC
Pressure
Fluid Class PO, RW, PW, GW, PA, IA, OW, FW, WW, PO, RW, PW, GW, FW, PA, IA, WW, CW,
CW, EC, WC EC, WC
Purpose Isolation – on/off Isolation – on/off
Type Bronze Gate Valve Metal Seated Gate Valve to AS2638.1 &
ASME B16.10
Construction Gate Gate – Rising stem
Max Operating 80ºC 95ºC
Temp
Ends NPT Female ANSI Class 150 RF flanges
Body Bronze Ductile Iron
Gate Bronze Ductile Iron
Stem Brass 316SS
Seat/Seals PTFE Bronze / graphite
Manufacturer Crane Australia: Australian Valve and Filter Industries:
(or equal) Class 200 Cast Bronze Gate Valve MSGV-RS Series
Cat. No. 424 PN16
Or approved equivalent Rising stem solid wedge gate valve
For above ground use only.
Manual Operator Hand wheel hand wheel
Note:  All valve operators shall have visual  All valve operators shall have visual
indication of valve state. indication of valve state.
 Valve may be included in piping hydro-
tests up to 2400kPag, but where the
hydro-test pressure exceeds 1800kPag,
the valve shall be kept open.
Page 185 of 236
100-SP-PI-0001_Rev 3
10.2.10 Gate Valves (Data Sheet 2 of 5)
GATE VALVES
Valve Class GA2A GA3
Max Working 1600kPa @ 80ºC 1600kPa @ 95C
Pressure
Fluid Class RW PO, RW, PW, GW, FW, WW
Type Metal seat gate valve Resilient seat gate valve to AWWA
C515/C509, ASME B16.10
Construction Gate – Rising stem Gate – Non-rising stem
Temp
Ends ANSI Class 150 RF flanges ANSI Class 150 RF flanges
Body Ductile Iron Ductile iron
Gate Ductile Iron Ductile iron, Vulcanised EPDM encapsulated
Seat/Seals Standard EPDM/NBR
Manufacturer Australian Valve and Filter Industries: Australian Valve and Filer Industries
(or equal) Figure MSGV-RS Series RSGV-A4703 Series Non- rising stem solid
PN16 wedge gate valve
Rising stem solid wedge gate valve For below ground use only.
For above ground use only. Or approved equivalent
Manual Operator Geared operator Removable key or spindle extension
Note:  All valve operators shall have visual  Specify for below ground service to
indication of valve state. supplier and ensure additional protective
coatings are applied
 Valve to be equipped with locker and
visual status indicator
 Valve may be included in piping hydro-
tests up to 3447kPag, but where the
hydro-test pressure exceeds 1723kPag,
the valve shall be kept open.
Page 186 of 236
100-SP-PI-0001_Rev 3
GATE VALVES
Valve Class GA3A GA4
Max Working 1600kPa @ 80ºC 1,600kPa @ 110ºC
Pressure
Fluid Class PO, RW, PW, GW, FW, OW, WW PO, RW, PW, GW, FW
Type Resilient seat gate valve Gate – rising stem
Size DN630 to DN1200 DN80 to DN300mm
Construction Gate – Non-rising stem Gate
Temp
Ends ANSI Class 150 RF flanges Victaulic grooved
Body Ductile iron Ductile iron
Gate Ductile iron Cast iron
Stem Stainless steel Brass
Seat/Seals Standard EPDM
Manufacturer Australian Valve and Filter Industries: Victaulic Series 771 OS&Y gate valve
(or equal) Figure RSGV-A47 For above ground use only.
PN16 Or approved equivalent
Non- rising stem solid wedge gate valve
For below ground use only.
Manual Operator Removable key and spindle extension, Hand wheel
geared operator
Note:  Specify for below ground service to  All valve operators shall have visual
supplier and ensure additional protective indication of valve state.
coatings are applied
Page 187 of 236
100-SP-PI-0001_Rev 3
GATE VALVES
Valve Class GA5 GA6
Max Working 1800kPa @ 90ºC 4000kPa @ 90ºC
Pressure
Fluid Class DO, OW, EO, GO, GRL, HO, TO, WO DO
Type Gate – Rising stem Gate – Rising stem
Size DN15 - DN600 DN15-600
(>DN350 requires gear operation)
Construction Rising stem, OS&Y solid wedge, bolted Rising stem, OS&Y solid wedge, bolted
bonnet bonnet
Temp
Ends Flanged RF Flanged RF
Body Forged Steel ASTM A105 Forged Steel ASTM A105
Cast Steel ASTM A216GR WCB Cast Steel ASTM A216GR WCB
Gate 13% Cr Steel API Trim Number 8 13% Cr Steel API Trim Number 8
Stem 13% Cr Steel API Trim Number 8 13% Cr Steel API Trim Number 8
Seat Hard Faced API Trim Number 8 Hard Faced API Trim Number 8
Packing Seal Reinforced Exfoliated Graphite Reinforced Exfoliated Graphite
Manufacturer DN15-40: VOGT Series 353 DN15-40 VOGT Series 363
(or equal) DN50-600: Crane Fig 47 XU DN50-600 Crane Fig 33 XU
Or approved equivalent Or approved equivalent

Manual Operator Handwheel, >DN350 Gear Operated Handwheel, >DN350 Gear Operated
Note:  Not to be used underground unless in a pit  Not to be used underground unless in a
due to exposed stem. pit due to exposed stem.
 Valve shall be fire safe and anti-static and  Valve shall be fire safe and anti-static
be regulatory approved and/or compliant and be regulatory approved and/or
for use in DO duty compliant for use in DO duty
Page 188 of 236
100-SP-PI-0001_Rev 3
GATE VALVES
Valve Class GA7
Max Working Pressure 12,400kPa @ 80ºC
Fluid Class DO, EO, GO, GRL, HO, TO, WO
Purpose Isolation – on/off
Type Gate – Rising stem
Size DN15 – DN50
Construction Metal seat gate valve, rising stem
Ends NPT Female
Body Carbon Steel
Gate Stainless Steel
Stem Austenitic Stainless Steel
Seat Stainless Steel
Manufacturer Crane gate valve:
(or equal) Cat #:FB-3604-XU-T
Manual Operator Handwheel
Note:  Not to be used underground unless in a pit due to exposed stem.
 Valve shall be fire safe and anti-static and be regulatory approved and/or
compliant for use in DO duty
Page 189 of 236
100-SP-PI-0001_Rev 3
10.2.14 Knife Gate Valves (Data Sheet 1 of 2)
KNIFE GATE VALVES – KG1 & KG2 (Page 1 of 2)

Valve Class KG1 KG2
Max Working Pressure 935kPa @ 50ºC Valve Size Pressure @ 50ºC
DN250 1,000kPa
DN300 1,000kPa
DN350 700kPa
DN400 600kPa
DN450 500kPa
DN500 400kPa
DN600 300kPa
Fluid Classes SL, TL SL, TL
Type Knife Gate – Rising stem Knife Gate – Rising stem
Ends Lugged body, drilled and tapped to suit Lugged body, drilled and tapped to suit
ANSI Class 150 RF flanges ANSI Class 150 RF flanges
Body SG Iron – Polyurethane lined SG Iron – Polyurethane lined
Gate Stainless Steel 316 Stainless Steel 316
Spindle Stainless Steel 303 Stainless Steel 303
Seat Urethane Polyurethane
Seat Deflector Cone Polyurethane Polyurethane
Manufacturer Keystone – F952, Trim No. 188 Keystone – F952, Trim No. 188
(or equal) Or approved equivalent. Or approved equivalent.
Operator Options:
Manual Operator Hand wheel – Non rising. Worm gear drive
Pneumatic Operator Optional - As detailed below, unless Optional - As detailed below, unless
specified otherwise on a specific specified otherwise on a specific
instrument data sheet. instrument data sheet.
Note:  All valve operators shall have visual  All valve operators shall have visual
indication of valve state. indication of valve state.
 Proximity switches for manually  Proximity switches for manually
operated valves as listed below operated valves as listed below
where specified where specified
Page 190 of 236
100-SP-PI-0001_Rev 3
KNIFE GATE VALVES – KG1 & KG2 (Page 2 of 2)

Pneumatic Operators, “On/Off” Service
Valve Class KG1
Valve Actuator Position Tyco Actuator Solenoid Valve Model Guarding Position
Size Type Indicator Model (See Note 3&4) (See Note 5) Monitoring
(See Note 1&2) (See Note 6)
DN80 Dbl Act Yes F738 P1 Asco - Product code: Tyco Gate IFM
VMG551B417MO 24DC Guard F951, Electronics,
DN100 Dbl Act Yes F738 P2 1 Piece, to Effector
5/2 Way, ¼” BSP Body
DN150 Dbl Act Yes F738 P3 Ported, Al Body, Press. 2 – suit valve Order
10 Bar Max, Manual Number:
DN200 Dbl Act Yes F738 P4 Override, Explosion IGT202
Protected Steel Enclosure
Epoxy Painted ‘Ex me’ 24VDC, IP67
Class 1 Zone 1 for required
IP67 rating
Valve Class KG2

Valve Actuator Position Tyco Actuator Solenoid Valve Model Guarding Position
Size Type Indicator Model (See Note 3&4) (See Note 5) Monitoring
(See Note 1&2) (See Note 6)
DN250 Dbl Act Yes F738 P6 SMC - Model: Tyco Shroud IFM
VFA5120-03 Kit F951, 304 Electronics,
DN300 Dbl Act Yes F738 P7 S/S, to suit Effector
5 Port Air Operated Valve
DN350 Dbl Act Yes F738 P8 valve Order
Asco - Product Code:
Number:
DN400 Dbl Act Yes F738 P10 WPG327B001MO 24DC
IGT202
3/2 single solenoid valve, ¼”
DN450 Dbl Act Yes F738 P13 BSP port, Brass body,
manual operator, epoxy 24VDC
DN500 Dbl Act Yes F738 P14
painted steel enclosure,
IP67, 24DC IP67
DN600 Dbl Act Yes F738 P15
 Asco solenoid valve to
provide pilot air to 5 port
SMC valve
Notes: 1. Shall be Tyco Figure 738 type actuators, size as per above listed Tyco Actuator Number for
corresponding knife gate valve size. Or approved equivalent.
2. Pneumatic control solenoid valve arrangements shall be as listed above for corresponding knife gate
valve size. Or approved equivalent.
3. Valve actuator fitted only where detailed on Project P&ID drawings and associated Valve Lists
4. Solenoid valve, and air operated valve where fitted, shall be factory mounted directly to each actuator
and hard pipe in stainless steel tubing.
5. Failure position of valve on loss of power only, (not loss of compressed air) to be as per Project P&ID
drawings and associated Valve Lists, unless otherwise specified
6. Guarding shall be fitted to each actuated valve
7. Position Monitoring of valves shall be fitted only where detailed on Project P&ID drawings and
associated Valve Lists
8. Each actuated valve is to be shipped from factory with the FMG valve tag number clearly identified
via a durable tag attached to the valve and displayed on packaging.
Page 191 of 236
100-SP-PI-0001_Rev 3
10.2.15 Knife Gate Valves (Data Sheet 2 of 2)
KNIFE GATE VALVES

Valve Class KG3
Max Working Pressure Valve Size Pressure @ 50ºC
DN250 – DN400 1,600kPa
DN450 – DN600 1,000kPa
Fluid Classes SL, TL
Purpose Isolation – on/off
Type Knife Gate – Rising stem
Size DN250 to DN600
Ends Lugged body, drilled and tapped to suit ANSI Class 150 RF flanges
Body SG Iron – Rilsan Lined
Gate Stainless Steel 316
Spindle Stainless Steel 304
Gland Packing K-LON
Seat Polyurethane
Fasteners Stainless Steel 304
Manufacturer Keystone – Figure 955, Trim Code 210
(or equal) Or approved equivalent.
Operator Options:
Manual Operator Worm gear drive with hand wheel
Pneumatic Operator Optional - As specified on a specific instrument data sheet.
Note:  All valve operators shall have visual indication of valve state.
 Proximity switch mounting plates to be optional
Page 192 of 236
100-SP-PI-0001_Rev 3
10.2.16 Non‐Return Valves (Data Sheet 1 of 3)
NON – RETURN VALVES

Valve Class NR1 NR2 NR3
Max Working Pressure 1,600kPa @ 80ºC 1,600kPa @ 50ºC 1,600kPa @ 50ºC
Fluid Classes PO, RW, PW, GW, FW, PO, RW, PW, GW, PA, PO, RW, PW, GW, PA,
PA, IA, SW, EC, WC IA, FW, OW, SW, WW, IA, FW, OW, SW, WW,
EC, WC EC, WC
Purpose Non-Return Non-Return Non-Return
Type Swing check Dual flap wafer Dual flap wafer
Size DN15 to DN50 DN50 to DN350 DN400 to DN600
Construction Threaded body Wafer body Lugged body
Max Operating Temp 90ºC 50ºC 50ºC
Ends NPT Female Wafer body – To suit Wafer body, - ANSI Class
ANSI class 150 150 RF flanges
Body Bronze Cast Iron Cast Iron
(For SW – CF8m, Cast (For SW – CF8m, Cast
Stainless Steel) Stainless Steel)
Seat/Seals PTFE Buna N Buna N
Discs 316 SS 316 SS
Springs Inconel X-750 Inconel X-750
Manufacturer Crane Australia: Flowserve Gestra - Disco Flowserve Gestra - Disco
(or equal) Class 150 Bronze Swing Or approved equivalent Or approved equivalent
Check Valve
Cat. No. 141TF
NPT female thread
Note:  Mating flanges for
wafer body non-return
valves shall be of the
Weld Neck style only
Page 193 of 236
100-SP-PI-0001_Rev 3

Valve Class NR3A NR3B NR4
Max Working 1,600kPa @ 50ºC 1,600kPa @ 50ºC 2065kPa @ 50ºC
Pressure
Fluid Classes RW RW PO, RW, PW, GW, FW, OW,
SW, WW
Type Silent and non-slam check Silent and non-slam check Single flap
valve valve
Size DN350 to DN500 DN600 to DN1200 DN80 to DN300
Construction Wafer body Flanged Body Grooved
Max Operating 50ºC 50ºC 50ºC
Temp
Ends Wafer body ANSI Class 150 RF flanges Victaulic groove
Body Ductile iron & Epoxy Ductile iron & Expoxy Ductile iron
Seat/Seals N/A N/A –
Disc Axial - Polyurethane Axial - Polyurethane PPS
Spring Stainless Steel Stainless Steel Grade “T” Nitrile
Manufacturer SAPAG CLASAR Or SAPAG CLASAR Or Victaulic, Series 716 Vic –
(or equal) approved equivalent approved equivalent Check.
Note: NR3A to be used for piping
class G1
Page 194 of 236
100-SP-PI-0001_Rev 3

Valve Class NR5 NR5B NR6
Max Working 1,800kPa @ 90ºC 4000kPag 1,600kPa @ 80ºC
Pressure 2,500kPa @ 80ºC
Fluid Classes DO, EO, HO, GO, TO , WO DO SL, TL
Type Piston (DN15-40) Swing Ball Check
Single flap (DN50-600)
Size DN15 to DN600 NB 25-150 DN80 to DN600
Construction Flanged Flanged Flanged
Max Op Temp 145°C (to maintain 90°C 80ºC
1600kPag rating)
Ends Flanged - ANSI Class 150 ANSI Class 300 RF Flanged - ANSI Class
RF 150 or 300 FF
Body Forged steel (DN15-40) ASTM A216-WCB / A105N Carbon steel – natural
Cast steel (DN50-600) rubber lined
Ball _ _ Carbon steel – urethane

coated
Seat Stellite / 13% Chrome 13% Cr / Stellite Roc-Tuf
API TRIM 8
Seal N/A
Manufacturer FLOWSERVE: VOGT 573 DN 15-40: VOGT 583 Dual Valves – Dual Free
(or equal) CRANE: 147 XU Flow Slurry Ballcheck
Valve
"Class 150 Forged Steel DN 50-250: VOGT 159XU
Piston Check VOGT Series Or approved equivalent
573
or “Class150 Cast Steel
Swing Check Valve Cat. No.
147 XU”
Note:  Valve DN15 to DN40  Valve shall be fire safe and Complete and detailed
VOGT Series 573 anti-static and be regulatory valve specifications
 Valve “147 XU” is DN50 to approved and/or compliant for shall be obtained from
DN600 use in DO duty the supplier for
 Valve shall be fire safe individual service
and anti-static and be applications and
regulatory approved approved by the
and/or compliant for use Principal prior to
in DO duty installation

Page 195 of 236
100-SP-PI-0001_Rev 3
10.2.19 Air Release Valves
AIR RELEASE / VACUUM BREAK VALVES

Valve Class: AV1 AV2 AV3
Description: Air Release Valve Air Release Valve Air Release Valve
Max Working Pressure: 1,600 kPa @ 80ºC 1,600 kPa @ 80ºC 2,500 kPa @80ºC
Fluid Class: PO, RW, PW PO, RW, PW SL, TL
Type: Automatic float Automatic float Floating ball
Size: DN25 – DN50 DN80 – DN200 DN50 to DN200
Max Operating Temp: 80ºC 80ºC 80ºC
End Connection: NPT-T, Male ANSI Class 150 RF ANSI Class 150 & Class
flange 300 RF flange –
application dependant
Body: 316 S/S body, 304 S/S 316 S/S body, Epoxy Carbon steel – natural
epoxy coated ends coated M/S flanges rubber lined internally
and epoxy coated
externally
Seals: EPDM EPDM 304 S/S & Linatex
Heat Shield: S/S top cover plate – S/S top cover plate – NA
heat shield heat shield
Operator: HDPE Float HDPE Float Guided urethane floating
ball
Manufacturer: Vent-O-Mat; Vent-O-Mat; Dual;
(or equal) Series: RBX Series: RBX Slurry air release valve
Or approved equivalent Or approved equivalent Or approved equivalent
Note: Complete and detailed
valve specifications shall
be obtained from the
supplier for individual
service applications and
prior to installation

Page 196 of 236
100-SP-PI-0001_Rev 3
10.2.20 Rotary Disc valve (Slurry / Tailings)
ROTARY DISC VALVE

Valve Class: RD1
Max Working Pressure: 2,500 kPa @ 80ºC
Fluid Class: TL
Purpose: Isolation – on/off
Type: Rotating disc – rising stem
Size: DN80 to DN450
Max Operating Temp: 80ºC
End Connection: ANSI Class 300 RF flanges
Face to Face Dimension: Standard
Body: Carbon steel
Body Lining: None
Body Seat: Carbon steel
Disc: Carbon steel – urethane faced
Wedge Back Plate: Carbon steel
Bonnet: Carbon steel
Packing: Graphite in rope
Gland: Carbon steel
Spindle: Stainless steel 304
Yoke Assembly: Carbon steel
Spindle Nut: Bronze
Manual Operator: DN80 – DN300 – Direct mounted hand wheel
DN350 To DN450 – Gear reduction drive mounted hand wheel
Manufacturer: Dual Valves (Australia)
(or equal) Dual Rotary Disc Valve
Note: –
Page 197 of 236
100-SP-PI-0001_Rev 3
10.3 Pneumatics
Note: Pneumatic components and fittings are specified with BSP threads as opposed to the
project standard of NPT for improved availability. Compatibility of ½” NPT and ½” BSP is
deemed acceptable for compressed air applications where required, nominally for connection to
BA1 ball valves for compressed air supply.
10.3.1 Compressed Air Tubing Fittings
Compressed Air Tubing Fittings

Class: NA
Description: Compressed Air Tubing Fittings
Max Operating Pressure: 1,000kPa @ 60ºC
Fluid Class: IA, PA
Nominal size: DN1/8 – DN1/2 Threaded Connection (BSP)
DN4 – DN16 Tubing Connection
Note: NPT & BSP compatibility deemed acceptable where required for DN15
Manufacturer: SMC - Model: KQ2 One-Touch Fittings
(or equal) Or approved equivalent
10.3.2 Compressed Air Tubing
Compressed Air Tubing

Class: T1
Description: Compressed Air Polyethylene Tubing
Fluid Class: IA, PA
Nominal size: 4mm to 16mm OD
Manufacturer: SMC – TE Series Polyethylene Tubing (all black)

Page 198 of 236
100-SP-PI-0001_Rev 3
10.3.3 Compressed Air Exhaust Silencer
Compressed Air Exhaust Silencer

Class: NA
Description: Compressed Air Exhaust Silencer
Fluid Class: IA, PA
Nominal size: DN6 to DN15 BSP
Manufacturer: SMC: Series 25
Data Sheet Extract:

Page 199 of 236
100-SP-PI-0001_Rev 3
10.3.4 Filter Regulator – FR1
Filter Regulator
Class: FR1
Description: Filter Regulator
Fluid Class: IA, PA
Nominal size: DN15 port (BSP)
Manufacturer: SMC:
(or equal) Filter Regulator Part Number: AW40-04-DE
Shutoff Valve Part Number: VHS40-04
Mounting Bracket/Connector Part Number: Y400T
Arrangement: As detailed below ( Location as approved by Principal)
Note: To be used only where specified on project P&ID drawings for compressed air supply to modulating control
valves or where approved by Principal
Data Sheet Extracts: Preferred Installation

Arrangement:
DN15 Ball Valve –
Class BA1
DN15 S/S Nipple
DN16 Compressed
Air Tubing
Compressed
Tube Fitting Air Header
(Typ.)
Mounting
Bracket to
column
1.5m
Above Grade
DN12 Compressed Air

Tubing to Control Valve
Page 200 of 236
100-SP-PI-0001_Rev 3
10.3.5 Auto Drain – AD1 (Compressed Air)
Auto Drain
Class: AD1
Description: Auto Drain Valve
Fluid Class: IA, PA
Nominal size: DN15 port (BSP)
Note: NPT & BSP compatibility deemed acceptable where required for
DN15
Manufacturer: SMC
(or equal) Model: AD402
Arrangement: As detailed below
Note: To be used only where specified on project P&ID drawings
Pipe support: For attachment to building columns use the below listed Binder system, unless
otherwise stated on Project Design Drawings or approved by the Principal on
an individual basis for alternative supports.
Binder: KS-1000 Channel, KS-235 Beam Clamp,
KS-2024 Series Channel Clip (size as required)
Data Sheet Extract: Preferred Installation
Arrangement:
Pipe
Support
As
detailed
above
DN15
Ball
Valve
Class
BA1
DN15
NPT
S/S
#3000
Nipple
Auto
Drain
Max. 1.0m

Page 201 of 236
100-SP-PI-0001_Rev 3
10.4 Miscellaneous Items
10.4.1 Pressure Gauge Assembly – PGC1 (Standard Applications)
Pressure Gauge Connection

Class: PGC1 Installation Arrangement:
Max Working Max. 2,400kPa @ 30ºC
Pressure: Note:
Dependant on actual piping
class and pressure gauge as Pressure Gauge
detailed below
Fluid Class: RW, PW, GW, IA, PA, DO
DN20xDN15 NPT Hex Reducing
Piping Class: A1, C1, C2, C3, C4, G1, G2, Bush
P1-P11, S1, S2, ,C5

Purpose: Pressure indication DN20 Ball Valve
Valve Class BA1
Type: Pressure Indication Gauge
Arrangement: As detailed DN20 NPT
Nipple
Pressure Gauge Ref. to P&ID for instrument
number and data sheet for
details DN20 NPT Female
Thread Connection
Gauge DN15 NPT Male Threadolet
Connection:
Note:
 To be used only where specified on project P&ID
drawings or approved by Principal
 Female thread connection to be in compliance
with individual piping classes
 Nipple and hex reducing bush shall be forged
3000# 316 stainless steel fittings for all piping
classes other than C3 and S4 which shall be
forged 6000# steel fittings
Pipe Run
 PTFE tape or thread seal compound shall be
used on all threaded connections
 Compatibility of seals/diaphragm/gauge with
Fluid Class Diesel Oil (DO) will need to be
checked
 Critical services such as Diesel Oil (DO) and
other Oil services (HO, EO, GO, GRL, WO, TO),
>1000kPa, shall have a block and bleed isolation
valve installed.
 All inline instrumentation shall be in accordance
with the Vendors installation requirements

Page 202 of 236
100-SP-PI-0001_Rev 3
10.4.2 Pressure Gauge Connection – PGC2 (Slurry Applications)

Class: PGC2 Installation Arrangement:
Max Working Max. 1,000kPa @ 30ºC
Pressure:
Fluid Class: SL
Piping Class: NA
Purpose: Pressure indication
Pressure Gauge & Plug Seal
Type: Pressure Indication Gauge
with NPT Hex Plug Seal
Arrangement: As detailed DN50 NPT Socket
304 S/Steel
Pressure Gauge Ref. to P&ID for instrument
& Plug Seal number and data sheet for
Assembly: details
Pressure Gauge DN50 NPT Male
Seal Connection: DN50 NPT Male Connection
on distributor top plate
Note:
 To be used only where specified on project P&ID
drawings or approved by Principal
 PTFE tape shall be used on all threaded
connections
 All inline instrumentation shall be in accordance
with the Vendors installation requirements
Primary Spirals Distributor
Top Plate
Page 203 of 236
100-SP-PI-0001_Rev 3
10.4.3 Pressure Gauge Connection – PGC3 (Slurry Applications)

Class: PGC3
Max Working 700kPa @ 30ºC
Pressure:
Fluid Class: SL, TL
Piping Class: R1, R3
Purpose: Pressure indication ANSI #150, FF
FLANGE AS PER PIPE
Type: Gauge with extended CLASS & REQUIRED
diaphragm seal SIZE
Arrangement: As detailed
Pressure Gauge Ref. to P&ID for
& Seal Assembly instrument number
and data sheet for
details
Gauge Seal DN80 ANSI flange,
Connection: class 150, FF
Note:
 To be used only where specified on
project P&ID drawings or approved by
Principal
 Spool section the same as that used in
PTC2, Section 10.4.5’
 All inline instrumentation shall be in
accordance with the Vendors installation
requirements
Page 204 of 236
100-SP-PI-0001_Rev 3
10.4.4 Pressure Transmitter Connection – PTC1 (Standard Applications)
Pressure Transmitter Connection

Class: PTC1
Max Working Max. 2,400kPa @
DN80 ANSI, FF
Pressure: 30ºC
FLANGE
Note:
FLANGE CLASS AS
Dependant on actual PER PIPE CLASS
piping class and
pressure transmitter
as detailed below
Fluid Class: PW, GW, RW, TL, DO
Piping Class: C1, C2, C3, C4, C6,
C7 G1, S2, C5
Purpose: Pressure
measurement
Type: Flange mounted
with extended
diaphragm seal
Pressure Ref. to P&ID for
Transmitter & instrument number AS PER
Seal Assembly and data sheet for PIPE
details CLASS
Transmitter Seal DN80 ANSI flange,

Connection: class (as per
transimitter), FF
Note:
Principal
 Compatibility of
seals/diaphragm/instrument with Fluid
Class Diesel Oil (DO) will need to be
checked
 An isolation valve shall be installed for
Fluid Class Diesel Oil (DO)
requirements
Page 205 of 236
100-SP-PI-0001_Rev 3
10.4.5 Pressure Transmitter Connection – PTC2 (Slurry Applications)
Pressure Transmitter Connection

Class: PTC2
Max Working 700kPa @ 30ºC
Pressure:
Fluid Class: SL, TL
Piping Class: R1, R3
ANSI #150, FF
Purpose: Pressure FLANGE AS PER
measurement PIPE CLASS &
REQUIRED SIZE
Type: Flange mounted
with extended
diaphragm seal
Pressure Ref. to P&ID for
Transmitter & instrument number
Seal Assembly and data sheet for
details
Transmitter Seal DN80 ANSI flange,
Connection: class 150, FF
Note:
Principal
 Spool section the same as that used in
PGC3, Section 10.4.3
requirements
 The pressure transmitter shall be
attached on the top of, and as close as
possible to the parent pipe.
Page 206 of 236
100-SP-PI-0001_Rev 3
10.4.6 Rubber Expansion Joint – EJ1 (Water, Standard Pressure)
Rubber Expansion Joint – EJ1 (Sheet 1 of 2)

Joint Class: EJ1
Fluid Class: RW, PW, GW
Max Working Pressure: As listed below
Max Working Vacuum: 88kPa (gauge)
Size: DN80 to DN900
Purpose: Pump vibration isolation and pipe work expansion compensation
Type: Single arch, flanged
Material: Tube and cover to be EPDM – UV stabilised
Ends: ANSI Class 150 FF flanges
Notes:  To be used only where specified on project P&ID drawings or approved by Principal
 For designations refer to the below diagram on Sheet 2 of 2.
 To be Tyco Flexonics expansion joints as listed below, or approved equivalent.
Dimension in (mm) Maximum allowable movements and forces
DN Max. Opp. Axial Lateral

Tyco Flexonics Face to Flange Arch ArchO. Thrust
Press Angular
Style Number face thickness width D. area deflection
(Bar) Comp Force Ext. Force Lateral Force
(deg)
mm F A G D W Cm² (mm) (n/mm) (mm) (n/mm) (mm) (n/mm)
80 HKF5-1L 164 153 111 144 143 9.1

14
100 HKF5-1L 13 190 216 12 148 6 192 166 7.6
150
150 HKF5-1L 16 245 369 222 288 215 4.6
10.5
200 HKF5-1L 311 611 246 321 263 5.4
250 HKF5-1L 19 360 855 308 401 282 4.3
300 HKF5-1L 417 1139 370 481 331 3.6

19 19 9
350 HKF5-1 494 1646 323 421 390 3.1
10 12
400 HKF5-1 22 544 2025 370 481 449 2.7
8.0
450 HKF5-1 595 2453 416 542 496 2.4
200
500 HKF5-1 650 2921 463 601 555 2.5
600 HKF5-1 7.0 756 3979 555 721 596 2.1
700 HKF5-1 25 22 869 5343 22 576 11 749 682 2.0
800 HKF5-1 6.5 971 6745 658 856 852 1.8
900 HKF5-1 1077 8312 740 963 1106 1.6
The below information shall be supplied when ordering any of the

Ordering Details: above Rubber Expansion Joints. Max. Op. Pressure MUST be
nominated.
Style
Size (DN): As Above As Above Max. Op. Pressure: As Above
Number:
Max Op. Backing Hot Dip Gal. Thrust Restraint List Individually
88kPa
Vacuum: Flange: Mild Steel Rods: as Required
Page 207 of 236
100-SP-PI-0001_Rev 3

Designations:
Axial Axial Elongation Torsional Lateral Angular Absorbing

Compression Movement Movement Movement Vibration
Page 208 of 236
100-SP-PI-0001_Rev 3
10.4.7 Rubber Expansion Joint – EJ2 (Water, High Pressure, Large Dia.)

Joint Class: EJ2
Fluid Class: RW, PW, GW
Max Working Pressure: 1,000kPa @ 30ºC
Size: DN80 to DN900
Type: Single arch, flanged
 Refer to below diagrams for designations on Sheet 2 of 2.
DN Tyco Flexonics Max. Dimension in (mm) Maximum allowable movements and forces
Opp. Face to Flange Arch ArchO.D. Thrust Axial Lateral Angular
Style Number Press face thickness width area deflection
Comp Force Ext. Force Lateral Force
(deg)
(mm) (n/mm) (mm) (n/mm) (mm) (n/mm)
mm (Bar) F A G D W Cm²
350 HKF5-1* 10.0* 22 494 1646 323 421 390 3.1

400 HKF5-1* 544 2025 370 481 449 2.7
450 HKF5-1* 595 2453 416 542 496 2.4
500 HKF5-1* 200 25 22 650 2921 22 463 11 601 555 2.5
600 HKF5-1* 10.0* 756 3979 555 721 596 2.1
700 HKF5-1* 10.0* 869 5343 576 749 682 2.0
800 HKF5-1* 971 6745 658 856 852 1.8
900 HKF5-1* 1077 8312 740 963 1106 1.6
Note: * = Special, pressure rating is non-standard, refer to below Ordering Details.
Ordering Details: The below information shall be supplied when ordering any of the above Rubber
Expansion Joints. Max. Op. Pressure MUST be nominated.
Size As Above Style Number: HKF5-1 Special Max. Op. Pressure: 1,000kPa
(DN):
Max Op. 88kPa Backing Hot Dip Gal. Mild Thrust Restraint Rods: List Individually
Vacuum: Flange: Steel as Required
Page 209 of 236
100-SP-PI-0001_Rev 3

Designations:
Axial Axial Elongation Torsional Lateral Angular Absorbing

Compression Movement Movement Movement Vibration
Page 210 of 236
100-SP-PI-0001_Rev 3
10.4.8 Rubber Expansion Joint – EJ3 (Slurry)
Rubber Expansion Joint – EJ3

Joint Class: EJ3
Fluid Class: SL, TL
Max Working Pressure: As listed below
Size: DN80 to DN450
Type: Double “Filled” Arch, Flanged
DN Tyco Flexonics Max. Dimension in (mm) Maximum allowable movements and forces
Opp. Face to Flange Arch ArchO.D. Thrust Axial Lateral Angular
Style Number Press face thickness width area deflection
length Comp Force Ext. Force Lateral Force
(deg)
(mm) (n/mm) (mm) (n/mm) (mm) (n/mm)
mm (Bar)
80 F22W 14.0 250 34 16 16 12.0

100 F22W 34 16 16 9.2
Refer to manufacturer
150 F22W 40 20 18 6.2
200 F22W 40 20 18 4.7
250 F22W 350 40 20 18 4.3
300 F22W 20 20 20 3.7
350 F22W 10.0 40 20 20 3.1
400 F22W 8.0 40 20 20 2.7
450 F22W 40 20 20 2.5
Ordering Details: The below information shall be supplied when ordering any of the above Rubber
Expansion Joints. Max. Op. Pressure MUST be nominated.
Size As Above Style Number: F22W Max. Op. Pressure: As Above

(DN):
Max Op. 88kPa Backing Hot Dip Gal. Mild Thrust Restraint Rods: List Individually
Vacuum: Flange: Steel as Required
Page 211 of 236
100-SP-PI-0001_Rev 3
10.4.9 Hose Rack
Hose Rack
Detail: Hose Rack
Paint Finish: Y15, Sunflower Yellow (AS2700)
Page 212 of 236
100-SP-PI-0001_Rev 3
10.5 Service Connection Data Sheets
10.5.1 General
All components of the below detailed Service Connection Classes shall be assembled and
installed in line with applicable Piping Class, accepted industry standards and practices, and
manufacturers requirements, particularly in the case of all hose and coupling assemblies and
the required service rating.
10.5.2 Service Connection Pipe Supports
Pipe Supports for stainless steel service connections shall be of the INSULATED type to
prevent local corrosion due to the dissimilar metals of the stainless steel pipe and carbon steel
structure/support members.
Depending on the individual installation and dropper length, each service connection shall be
supported by two sturdy supports such as insulated U-bolts or saddles as indicated in the
following data sheets to provide adequate support strength in relation to the attached hose and
its use, unless otherwise detailed on Project design drawings or approved by the Principal.
Refer to drawing CO-0000-DR-PI-0013, Service Connection Typical Arrangement & Details, for
typical multiple service connection arrangements and supports.
10.5.3 Service Connection Class – SC1
Service Connection Class – SC1 (Sheet 1 of 2)

Type: DN25 Wash Down Water Point
Fluid Class: RW, PW
Pressure range : Max. 1,600kPa @ 70ºC
Construction: Refer to assembly sketch below.
Wash down Water Points shall be as detailed below in relation to valve, orifice fitting and
coupling arrangement, with piping to be in Piping Class G1 by default, unless otherwise
specified on applicable P&ID drawings or approved by the Principal
Item Description Quantity
1 Supply header NA
2 Pipe dropper (riser) to wash down point – configuration as required. NA
3 Male Threaded connection. As Req’d
4 DN25 Ball Valve – Valve Class BA1 1 off
5 DN25 x DN25 NPT male, Minsup Surelock claw coupling 1 off
Dixon Part No. 08/013/14/001
6 Pipe Supports – As per Section 10.5.2 As Req’d
Page 213 of 236
100-SP-PI-0001_Rev 3
Hose: Not installed –
Hose Rack: Not installed –

Detail: Dropper Assembly
5
1200-1500mm
Above Grade
Page 214 of 236
100-SP-PI-0001_Rev 3

Type: DN25 Wash Down Water Point – complete with Hose, Nozzle & Hose Rack
Fluid Class: RW, PW
1 Supply header NA
3 Male Threaded connection. As Req’d
5 DN25 x DN25 NPT male, Type A stainless steel, standard seal claw coupling 1 off
Hose: DN25mm x 20m long heavy duty wash down hose. Working pressure rating 20bar 1 off
c/w 500mm spiral hose guard and shrink wrap at both ends
Hose DN25 x DN25 hose tail, Type A stainless steel, standard seal claw coupling with 1 off
Coupling 1: crimped ferrule and safety pin
Hose 25mm x 20mm “boss” male stem hose tail, crimped with male BSP end (Dixon 1 off
Coupling 2: Part No.M16x12A)
Hose Crimped ferrule 2 off
Clamps:
Nozzle: DN20mm Brass Blackout Nozzle c/w; 1 off
1 off 300mm long DN20mm Sch80 Galv. BSP male threaded pipe.
2 off DN20mm galv BSP sockets
Hose Rack: Hose Rack as per sketch in Section 10.4.9 – site mount to building columns by 1 off
welding two pieces of Binder KS-1000 Channel to the back of it and attaching via
Binder KS-235 Beam Clamps, or as detailed on Project Design Drawings or
Page 215 of 236
100-SP-PI-0001_Rev 3

Type: DN25 Wash Down Water Point – complete with Hose and Hose Rack
5
1200-1500mm
Above Grade
Page 216 of 236
100-SP-PI-0001_Rev 3

Fluid Class: RW, PW
1 Supply header NA
3 Female Threaded connection for orifice fitting, male threaded connection to be used As Req’d
if no orifice fitting is specified in table below.
4 DN40 Orifice Fitting (refer to below table & arrangement) As Req’d
Dixon Part No. 08/013/07/001
Hose Rack: Not installed –

Page 217 of 236
100-SP-PI-0001_Rev 3

Details: Item 4: Orifice Fitting selection based on Location as detailed below
Port Cloud Break Mine Cloud Break Desand Plant
RL Orifice RL Orifice All Cases:
All 23mm All 23mm No orifice fitting required.
Note: For Orifice fitting details refer to Drawing 00010-PI-DR-1212
Alternative;
3
Replace with male threaded
adapter (or similar) if no
4 orifice fitting is required.
5
6
1200-1500mm
Above Grade
Page 218 of 236
100-SP-PI-0001_Rev 3

Type: DN40 Wash Down Water Point complete with 20m Hose, Nozzle & Hose Rack
Fluid Class: RW, PW
1 Supply header NA
4 DN40 Orifice Fitting (refer to below table & arrangement) Not Req’d
6 DN32 x DN32 NPT male, Type A stainless steel, standard seal claw coupling c/w 1 off
40mm M x 32mm F NPT stainless steel reducing fitting
Hose: DN32 x 20m long Totalflex Multi Series 11 RMD1032 rubber hose (or approved 1 off
equivalent) c/w 500mm spiral hose guard and shrink wrap at both ends
Hose 40mm (thread) x 32mm (hose end) hose tail, crimped with male BSP end 1 off
Coupling 2:
Clamps:
Nozzle: 40mm Brass jet/spray nozzle, with DN40mm BSP female thread. 310L/min (jet) 1 off
400L/min (spray) at 448kPa (Dixon Part No. WRS103-GM-38-NA)
(Must be rated for 16bar maximum pressure)
Page 219 of 236
100-SP-PI-0001_Rev 3

Type: DN40 Wash Down Water Point complete with Hose and Hose Rack
Details: Item 4: Orifice Fitting selection based on Location as detailed below.
All Not required All Not required No orifice fitting required.
Alternative;
3
5
6
1200-1500mm
Above Grade
Page 220 of 236
100-SP-PI-0001_Rev 3

Type: DN20 Compressed Air Dropper
Fluid Class: PA, PI
Compressed air droppers shall be as detailed below in relation to valve, pressure bleed,
silencer, drain and coupling arrangement, with piping to be in Piping Class S1 by default,
unless otherwise specified on applicable P&ID drawings or approved by the Principal
1 Compressed Air supply header NA

2 DN25 Pipe dropper to valve assembly – top exit from header. Configuration as NA
required
3 DN25 Tee with DN25 female threaded branch 1 off
4 DN25 NPT Nipple 1 off
5 DN25 3-way ball valve, Valve Class BA4 1 off
6 DN25xDN20 NPT hex reducing bush 1 off
7 DN20x DN20 NPT male, Minsup Surelock claw coupling. 1 off
Dixon Part No. 08/013/17/001
8 DN25xDN15 female threaded adaptor 1 off
9 Brass Drain Cock, ½” BSP (compatibility acceptable) 1 off
Blackwoods Part No. 08069519
10 DN25xDN15 NPT Hex Reducing Bush 1 off
11 DN15 BSP Brass Male/Female Elbow (compatibility acceptable) 2 off
12 DN15 Air Silencer, SMC Model 2506-N-004 1 off
Hose: Not Installed NA
Hose Rack: Not Installed NA
Page 221 of 236
100-SP-PI-0001_Rev 3

Type: DN20 Compressed Air Dropper
Detail: Compressed Air Dropper Assembly
13
Preferred valve “off”

position in this
direction & location
(Off at horizontal)
Preferred valve
11 “on“ position in
this location
10
12
5
3
6
4
1200-1500mm 7
300mm
Above Grade
8
9
Page 222 of 236
100-SP-PI-0001_Rev 3

Type: DN20 Plant Air Dropper – Complete with Air Hose and Hose Rack
Fluid Class: PA, PI
Compressed air droppers shall be as detailed below in relation to valve, pressure bleed,
silencer, drain and coupling arrangement, with piping to be in Piping Class S1 by default,
unless otherwise specified on applicable P&ID drawings or approved by the Principal

1 Compressed Air supply header NA
2 DN25 Pipe dropper – top exit from header. Configuration as required NA
3 DN25 Tee with DN25 female threaded branch 1 off
4 DN25 NPT Nipple 1 off
5 DN25 3-way ball valve, Valve Class BA4 1 off
6 DN25xDN20 NPT hex reducing bush 1 off
7 DN20x DN20 NPT male, Minsup Surelock claw coupling. 1 off
Dixon Part No. 08/013/17/001
8 DN25xDN15 female threaded adaptor 1 off
9 Brass Drain Cock, ½” BSP (compatibility acceptable) 1 off
Blackwoods Part No. 08069519
10 DN25xDN15 NPT Hex Reducing Bush 1 off
11 DN15 BSP Brass Male/Female Elbow (compatibility acceptable) 2 off
12 DN15 Air Silencer, SMC Model 2506-N-004 1 off
Hose: DN20 x 20m long Dixon A191 – Super heavy duty air & water 300 PSI delivery hose. 1 off
Dixon Part Number: A19102020 (or approved equivalent)
Hose DN20 x DN20 hose tail, Minsup Surelock claw coupling 2 off
Coupling: Dixon Part No. 08/013/19/000
Hose Minsup double bolt claw clamp, Dixon Part No. 08/023/43/000 2 off
Clamp:
Hose Hose Rack as per sketch in Section 10.4.9 – site mount to building columns by welding 1 off
Rack: two pieces of Binder KS-1000 Channel to the back of it and attaching via Binder KS-
235 Beam Clamps, or as detailed on Project Design Drawings or approved by Principal
prior to installation on an individual basis.
Page 223 of 236
100-SP-PI-0001_Rev 3

Type: DN20 Plant Air Dropper – Complete with Air Hose and Hose Rack
Detail: Compressed Air Dropper Assembly
13
Preferred valve “off”

position in this
direction & location
(Off at horizontal)
Preferred valve
11 “on“ position in
this location
10
12
5
3
1200-1500mm 6
4
Above Grade 300mm
7
8
9
Page 224 of 236
100-SP-PI-0001_Rev 3

Fluid Class: RW, PW
1 Supply header NA
3 Female Threaded connection for orifice fitting, male threaded connection to be used if no As Req’d
orifice fitting is specified in table below.
Dixon Part No. 08/013/04/001
Hose Not installed –

Rack:
Page 225 of 236
100-SP-PI-0001_Rev 3



Alternative;
3
5
6
1200-1500mm
Above Grade
Page 226 of 236
100-SP-PI-0001_Rev 3

Type: DN50 Wash Down Water Point – Complete with Hose and Hose Rack
Fluid Class: RW, PW
1 Supply header NA
6 DN50 x DN50 NPT male, Minsup Surelock claw coupling off
Dixon Part No. 08/013/04/001 (1 x dropper valve)
Hose: DN50 x 20m long Dixon A191 – Super heavy duty air & water 300 PSI delivery 1 off
hose. Dixon Part Number: A19105020 (or approved equivalent)
Hose DN50 x DN50 hose tail, Minsup Surelock claw coupling 2 off
Coupling: Dixon Part No. 08/013/06/000
Hose Minsup double bolt claw clamp, Dixon Part No. 08/023/03/000 2 off
Clamp:
Nozzle: 50mm CMM Branchpipe with curtain (male BSP thread). 1 off
(Rated for 16bar maximum operating pressure)
Tyco Fire & Security, Part No. CMM
To be fitted with 1 off DN50xDN50 BSP Female Minsup Surelock claw coupling for
connection to hose. Dixon Part No. 08/013/05/000
Hose Hose Rack as per sketch in Section 10.4.9 – site mount to building columns by 1 off
Rack: welding two pieces of Binder KS-1000 Channel to the back of it and attaching via
Page 227 of 236
100-SP-PI-0001_Rev 3

Type: DN50 Wash Down Water Point – Complete with Hose and Hose Rack
Details: Item 4: Orifice Fitting selection based on Location as detailed below


Alternative;
3
5
6
1200-1500mm
Above Grade
Page 228 of 236
100-SP-PI-0001_Rev 3

Type: DN40 Wash Down Water Point complete with 40m Hose, Nozzle & Hose Rack
Fluid Class: RW, PW
1 Supply header NA
4 DN40 Orifice Fitting (refer to below table & arrangement) Not Req’d
6 DN32 x DN32 NPT male, Type A stainless steel, standard seal claw coupling c/w 1 off
40mm M x 32mm F NPT stainless steel reducing fitting
Hose: DN32 x 40m long Totalflex Multi Series 11 RMD1032 rubber hose (or approved 1 off
equivalent) c/w 500mm spiral hose guard and shrink wrap at both ends
Hose 40mm (thread) x 32mm (hose end) hose tail, crimped with male BSP end 1 off
Coupling 2:
Clamps:
Nozzle: 40mm Brass jet/spray nozzle, with DN40mm BSP female thread. 310L/min (jet) 1 off
400L/min (spray) at 448kPa (Dixon Part No. WRS103-GM-38-NA)
(Must be rated for 16bar maximum pressure)
Page 229 of 236
100-SP-PI-0001_Rev 3

Type: DN40 Wash Down Water Point complete with Hose and Hose Rack
All Not required All Not required No orifice fitting required.
Alternative;
3
5
6
1200-1500mm
Above Grade
Page 230 of 236
100-SP-PI-0001_Rev 3
10.5.12 Service Connection Class – FH1
FIRE HYDRANT – FH1

Valve type Fire Hydrant riser assembly
Valve size DN 65 x 2
Duty Fire Hydrant for quick action fire hose connection
o
Temperature range, up to 80 C
Product handled Fire Water
Riser 1 off Galvin GE Galvanised Fire Hydrant Pipe Riser with T-Head, Flanged Vertical Inlet
100 x 1150 Long (not painted red – see note 3).
Part No. 381343 (Note: Standard as DN100 Table E flange connection)
Hydrant Valves 2 off Galvin GE BS fire hydrant valves: Part No. 381301
Valves to be complete with cap and chain: Part No. 380550
Notes: 1. Alternative assemblies shall be submitted for prior approval

2. Valve and assembly shall be compliant with AS 2419
3. Galvanised riser must be painted R13 Signal Red upon installation as per
Standard Engineering Specification Protective Coating Systems – Painting
100-SP-ST-0004.
4. Standard fire hydrant general details can be found in 07000-IF-DR-0013.
# 381343 – GE
Galvanised Fire Hydrant
Pipe Riser with T-Head,
Flanged Vertical Inlet DN100 x 1150 Long
(Painted upon installation).
Page 231 of 236
100-SP-PI-0001_Rev 3
10.5.13 Service Connection Class –FH2
FIRE HOSE REEL – FH2

Equipment type Fire Hose Reel
Valve size DN 25 isolation, 36m x 19mm hose
Duty Fire Hose reel to AS1221
Construction Stainless steel side plates, acetal copolymer gland, stainless steel spindle, acetal
copolymer bearing, stainless steel pipe fittings, stainless steel drum, stainless
steel nozzle.
Acceptable valves Wormald fire hose reel: 92-485P, or approved equivalent.

Hose Reel assembly shall be compliant with AS 1221
Page 232 of 236
100-SP-PI-0001_Rev 3

Valve size DN 65 x 2
Duty Dual Fire Hydrant for quick action fire hose connection
Temperature range, up to 80oC
Riser DN100 Riser to be in Piping Class G2 as specified within, complete with a GE brass
fire hydrant valve dual head 100CU/roll groove x 65 FI BSP. (Galvin Part No.
381325)
Riser length and supports to be as per individual locations and requirements in line
with Project Drawings.
Hydrant Valves 2 off Galvin GE BS fire hydrant valves:

Part No. 381301
Valves to be complete with cap and chain:
Part No. 380550
Notes: Alternative assemblies shall be submitted for prior approval

Valve and assembly shall be compliant with AS 2419
Page 233 of 236
100-SP-PI-0001_Rev 3

Valve size DN 65 (DN80 grooved connection)
Duty Fire Hydrant with quick action fire hose connection
Temperature range, up to 80oC
Product Fire Water

handled
Riser Riser to be in Piping Class G2 as specified within.

Riser length and supports to be as per individual locations and requirements in line with Project
Drawings.
Hydrant Valves 1 off Galvin GE BS fire hydrant valve:

Part No. 381301RG
Valve to be complete with cap and chain: Part No. 380550
Notes: Alternative assemblies shall be submitted for prior approval

Valve and assembly shall be compliant with AS 2419

Page 234 of 236
100-SP-PI-0001_Rev 3
Appendix 1: Installation Details

Page 235 of 236
100-SP-PI-0001_Rev 3
Valves
Stud bolts and nuts are to be tightened down uniformly at diametrically opposed points.
Typical tighten down sequence is shown below –
Maximum torque’s
1st sequence approximately 50%
2nd sequence approximately 80%
3rd sequence 100%
Torque ratings are to be as per Vendor Specifications.
Actuators are to be installed in the vertical position.
For Butterfly valves-
 install the valve with the shaft in the horizontal position.
 To avoid damage to the valve disc during installation, open pipework to allow free valve
entry. (Valve disc should be in semi-closed position).
 Valve in semi-closed position to protect the edge of disc, avoid compression on seat
during installation so to help in the reduction of initial torque. (Note do not install with
disc in fully closed position as this will cause seat distortion)
 During installation stroke the valve after the 1st and 3rd tighten down sequence, making
sure the valve is operating correctly and the disc is not striking the pipe work.
Magnetic Flowmeters
Flowtubes are shipped with end covers to protect it from mechanical damage and normal
unrestrained distortion. These end covers should only be removed just before installation.
Follow Vendor lifting and transportation guidelines; however every precaution should be taken
to avoid liner damage.
To ensure specific accuracy install the flowtube with a minimum of five straight pipe diameters
upstream and two pipe diameters downstream from the electrode plane.
Align the piping to minimize axial and lateral pipe stresses imposed on the flowtube fittings and
flange bolts. DO NOT use the flowtube to align the piping.
The flowtube requires gaskets at each of its connections to adjacent equipment or piping. The
gasket material must be compatible with the process fluid and operating conditions, and must
not damage the liner.
Page 236 of 236
100-SP-PI-0001_Rev 3
Flange Gaskets with non-attached Grounding Rings
Flange Gaskets with attached Grounding Rings

Stud bolts and nuts are to be tightened down uniformly at diametrically opposed points as
detailed above.

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Specification

Standard Engineering Specification

1. SCOPE .............................................................................................................................. 14

2. LOCATION AND ENVIRONMENTAL CONDITIONS ................................................................. 14

3. CODES, STANDARDS, SPECIFICATIONS AND REGULATIONS .................................................. 14

4. RELATED DOCUMENTS ...................................................................................................... 19

5. ABBREVIATIONS ............................................................................................................... 19

6. GENERAL .......................................................................................................................... 21

7. PIPING SERVICE AND CLASSES ........................................................................................... 22

8. PIPING SPECIFICATION ...................................................................................................... 26

9. VALVE SPECIFICATION ....................................................................................................... 91

10. DATA SHEETS.................................................................................................................. 101

Table 1: Government Acts, Codes and Regulations ........................................................... 14

Table 1: Government Acts, Codes and Regulations

Table 2: Australian Standards

AS 1214 Hot-dip Galvanised Coatings on Threaded Fasteners

AS 1221 Fire Hose Reels

Document No. Title

Table 3: International Standards

Table 4: British Standards

Document No. Title

Table 5: American Standards

Document No. Title

Table 6: Company Standards, Specifications and Procedures

This document has references to the following Drawings:

Table 7: Associated Drawings

The following items are outside the Scope of this Specification:

 High temperature piping above 100°C,

 Piping for corrosive chemicals,

 High pressure or specialized duty piping,

 Piping system commissioning.

Table 9: Fluid Service Definitions

Table 10: Piping Class/Duty Summary

PIPING CLASS and DUTY SUMMARY

PIPING CLASS and DUTY SUMMARY

Table 11: Pipe Service and Colour Table

CW Chilled water Jade G21

WO Waste Oil Golden Tan X53

WW Waste water Black -

*Indicates supplementary colour required to AS1345

 Carbon steel DN50 or less

 Stainless steel DN50 or less

 As alternatively detailed on design drawings

 For connection to pre-fabricated flanged fire hydrant riser assemblies

Pressure/temperature ratings of flanged components shall be as per the respective standard.

Table 12: Maximum Deviation for Flange Face Alignment

See Appendix 1 for flange tightening details

Flanged connections shall be tightened sequentially diagonally opposite in a clockwise or

8.1.5.1 Carbon Steel and Stainless Steel Flange Bolt Torques

Table 13: Carbon/Stainless Steel Flange Bolt Torques

Inside ends of threaded pipes shall be deburred by reaming.

All threaded connections shall be gauge-checked or chased after galvanising.

Table 14: Linear Dimensional Tolerances for Pipe Fabricated Spools

DESCRIPTION LINEAR TOLERANCE

Length Less than 1.5 m Length 1.5 m and Longer

End to End ± 1.5 mm ± 3.0 mm

8.1.8.1 Stainless Steel Pipe Work

Tools used for fabrication of stainless steel shall be clearly identified.

Table 15: Misalignment Tolerance

Repair procedures shall be approved by the Principal prior to commencement of work.

Pipe line identification shall be in accordance with AS 1345 and AS 2700.

Surface protection paint shall not be applied to:

 Stainless steel piping,