VEDANTA LIMITED

Lanjigarh 5.0 Mtpa Expansion Basic

Engineering
Piping Standard

Document No Rev C: 311001-00064-000-PE-STD-0001

06 Oct 2020

Blue Tower, Level 25

12 Creek Street
Brisbane QLD 4000
Australia
T: +61 7 3239 7400
Worley Services Pty Ltd
ABN 61 001 279 812

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Synopsis

Worley Project Execution Plan for the Basic Engineering study of Lanjigarh 5.0Mtpa Expansion

Disclaimer

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PROJECT 311001-00064 - Lanjigarh 5.0 Mtpa Expansion Basic Engineering – Piping Standard

WorleyParsons Customer
Rev Description Original Review Date Date
Approval Approval
A For Internal Discipline
Review 24 Sept 2020
KA JR - N/A N/A

Khristele Ablog John Robinson N/A

B For Squad Check
KA JR - 25 Sept 2020 N/A N/A

Khristele Ablog John Robinson N/A

C For Client Review Khristele Ablog
2020.10.06
Digitally signed by
John Robinson
15:53:33
06 Oct 2020
Date: 2020.10.06
+10'00' 16:01:38+10'00'

Khristele Ablog John Robinson Ron van der

Kevie

311001-00064-000-PE-STD-0001_C Piping Standard ii

 Contents
1. Scope ................................................................................................................................... 1
1.1 Abbreviations.................................................................................................................. 1
1.2 Exclusions ....................................................................................................................... 1
1.3 Standards ........................................................................................................................ 2
2. Bayer Process Fluid Services ................................................................................................. 3
2.1 Process Fluids ................................................................................................................. 3
2.2 Process Cleaning Fluids ................................................................................................... 3
2.3 Process Utilities and Reagents ........................................................................................ 3
2.4 Fluid Service Summary ................................................................................................... 4
3. Specifications for Materials and Components ...................................................................... 6
3.1 Applicable Specifications ................................................................................................ 6
3.2 Piping and Fittings .......................................................................................................... 6
3.3 Preferred Pipe Sizes ........................................................................................................ 8
3.4 Valves.............................................................................................................................. 8
3.5 Gaskets ........................................................................................................................... 9
4. Insulation ........................................................................................................................... 10
4.1 General ......................................................................................................................... 10
4.2 Insulation for Personnel Protection.............................................................................. 10
4.3 Insulation Materials ...................................................................................................... 11
4.4 Cladding Materials ........................................................................................................ 12
5. Pipeline Number System .................................................................................................... 13
5.1 Pipeline Designation ..................................................................................................... 13
6. Pipe System Specifications ................................................................................................. 14
6.1 Pipe Specifications ........................................................................................................ 14

Appendices
Appendix A. Piping Class Specification Sheets .............................................................................. 1
Appendix B. Piping Branch Chart .................................................................................................. 1
Appendix C. Valves for Alumina Plant Services ............................................................................. 1
Appendix D. Insulation Thickness ................................................................................................. 1
Appendix E. Instrument Process Connections ............................................................................... 1
Appendix F. Caustic Soda Service Chart ........................................................................................ 1

311001-00064-000-PE-STD-0001_C Piping Standard iii

 1. Scope
This Basic Engineering piping standard provides recommended selections for piping materials and
components to service the Lanjigarh 5.0 Mtpa Expansion Project alumina plant fluid services. It will
supplement existing international codes and specifications. This is to ensure that the plant will be
operable and maintainable by setting standards which are based on good practice and on
operational experience from similar alumina plants.

Specifications for components are generally related to ASME Standards for design, dimensions and
component ratings. Specifications for components are to ASTM Standards for materials.

The piping specifications are categorised under various "classes" depending on the maximum
operating pressures and temperatures, the type of service and the type of valves required. The
classes are identified by a three (3) character code designating general rating and base material. The
piping service classes are listed in Appendix A.

This standard is to be read in conjunction with the latest revision of the Basis of Design document
(Doc. No. 311001-00064-00E-GE-BOD-0001).

1.1 Abbreviations
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
ASTM : American Society for Testing and Materials
SI : Système Internationale D'Unitès
MSS : Manufacturers' Standardisation Society of the Valve and Fittings Industry
FV : Full Vacuum. Set at minus 96.2kPa(g) for Lanjigarh 5.0 Mtpa Expansion project

1.2 Exclusions
The following piping systems are excluded:

 boiler plant, or other piping within steam power stations

 domestic utility services such as water supply and sewerage, heating/ventilating and
air-conditioning
Methods of construction, testing or commissioning are not specifically addressed except by
reference to the various international, national and Worley standards. Hydraulic design issues are
covered in the latest revision of the Piping and Pumping System Design Standard Document No.
311001-00064-000-PE-STD-0002.

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 1.3 Standards
The design shall be in accordance with international, national and Worley standards as defined and
referenced in latest revision of the Basis of Design document (Doc. No. 311001-00064-00E-GE-BOD-
0001) for the Lanjigarh 5.0 Mtpa Expansion Project.

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 2. Bayer Process Fluid Services
The process fluids in the Bayer process consist of various liquor solutions and caustic slurries. These
fluids are generally compatible with carbon steel piping.

Piping exposed either internally or externally to caustic liquors, slurries or fumes shall not have any
components made of non-ferrous materials susceptible to caustic attack, such as aluminium, zinc,
copper or related alloys.

2.1 Process Fluids

A separate piping class specification is defined for each of the different process streams. Refer to
Table 2-1 Fluid Service Summary. The fluid service descriptions listed cover the majority of the
process and utility fluids in the plant for the purpose of this Basic Engineering design.

2.2 Process Cleaning Fluids

A number of chemical solutions are commonly used to remove scale from process piping and
equipment. Typical chemicals are listed below:

 Caustic Cleaning Liquor.

 Concentrated and/or Dilute Sulphuric Acid.
 Hydrochloric Acid.
 Nitric Acid.
Lines which are utilised regularly for process cleaning fluids shall generally be of the specification
applicable to that service.

These fluids have particular material compatibility requirements. Acids require piping which is
chemically resistant to attack. Caustic cleaning liquor at high concentrations and temperatures
causes long-term stress corrosion cracking of welds. Although the carbon steel pipe material is itself
resistant, it is prudent to avoid excessive restraint (which leads to thermal expansion stress), and to
stress-relieve welds in large or critical pipe work used frequently for caustic cleaning liquor.

2.3 Process Utilities and Reagents

Process utilities required in Bayer refineries are mostly similar to those used in many other process
plants. Reagent fluids are used as inputs to the process.

The caustic external environment precludes use of non-ferrous metals in the plant. The main utility
and reagent piping services are:

 Live Steam  Fire Water

 Plant Air  Hosing Water
 Instrument Air  Cooling Water
 Potable Water  Instrument Purge Water

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  Gland Water  Lubricant
 Fuel Oil  Sulphuric Acid
 Raw Caustic Soda Solution  Hydrochloric Acid
 Liquid Flocculants

2.4 Fluid Service Summary

Table 2-1 provides a listing of the alumina plant fluid services with their respective Service Codes (for use
in Line Numberings). Typical process conditions are indicated.

Refer also to the Summary of Piping Classes in Appendix A which lists all of the Services by Piping Class.

Table 2-1 Fluid Service Summary

Fluid Service Service Temp Caustic Abrasive / Pipe Class

Corrosive
Code (oC) g/L Na2O
Process Liquors
Washer Overflow WO <110 <135 - 1C7
Hydrate Filtrate FLT <110 <135 - 1C7
Pregnant Liquor PL <110 <130 - 1C7
Hot Spent Liquor SLH <170 <200 - 1C7
Spent Liquor SL <110 <200 1C7 / 3C3
Process Water PW <60 <20 - 1C5
Residue Disposal Liquor RDL <35 <20 - 1C3
Weak Liquor WCL <90 <65 - 1C7
Flushing Liquor FLI <90 <160 - 1C7
Digestion Vent DV <190 <160 - 1C8

Process Slurries
Bauxite Slurry BSL <110 <155 A 1C8
Mud Slurry MSL <110 <130 A 1C8
Digestion Feed Slurries DFS <110 <160 A 1C8 / 3C3
Digestion Slurries DSL <170 <160 A 1C8
Blow Off Slurries BOS <110 <160 1C8
Residue Mud Slurries RMS <65 <25 3C2 / 6C1
Hydrate Slurries HSL <110 <135 - 1C7
Fine Seed Slurries FSL <110 <85 - 1C7
Oxalate Slurries OSL <110 <25 - 1C3
Lime Slurry LSL <110 <1 1C7
Tricalcium Aluminate TCA <110 <135 1C7
Cleaning Liquors
Caustic Cleaning Liquor CCL <110 <650 - 1C7
Cleaning Liquor Used CLU <110 <650 - 1C7

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 Fluid Service Service Temp Caustic Abrasive / Pipe Class
Corrosive
Code (oC) g/L Na2O
Dilute Sulphuric Acid <10% DSA <60 N/A C 1C10
Concentrated Sulphuric 98% CSA <60 N/A C 1C6
Hydrochloric Acid 5%-33% HCL <60 N/A C 1C10

Utilities and Reagents

Plant Air PA <60 N/A - 1C5
Blower Air BA <80 N/A - 1C5
Instrument Air IA <60 N/A - 1C5
Vacuum VC <110 N/A - 1C5
High Pressure Steam (10 bar) HPS <270 N/A - 1C2
(Hold)
Low Pressure Steam (6 bar) LPS <270 N/A - 1C2
High Press Steam Condensate HSC <270 N/A - 1C2
Low Press Steam Condensate LSC <270 N/A - 1C2
Flash Vapour FV <200 N/A - 1C2
Flash Condensate FLC <170 <1 - 1C3
Cleaning Condensate CON <100 <1 - 1C3

Drinking Water DW <60 N/A - 1C5

Filtered Raw Water FRW <60 N/A - 1C5
Raw Water RW <60 N/A - 1C5
Fire Water FW <100 N/A - 1C5
De-Mineralised Water DMW <60 N/A - 1S1
Sump Water SW <100 <650 - 1C5
Hosing (Industrial) Water HW <100 <25 - 1C5
Alkaline Cooling Water ACW <100 <10 - 1C5
Non-Alkaline Cooling Water NCW <100 <10 1C5
Instrument Purging Water IPW <110 <1 - 1C4
Gland Water GW <110 <25 - 1C4
Raw (Fresh) Caustic CAU <60 <600 - 1C6
Anti-Foam Reagent AFR <60 N/A - 1C5
Drainage Aid DRA <60 <25 - 1C5
Flocculant FLO <60 Varies - 1C5
General Chemical Services GCS <60 N/A - 1C5

Oils and Fuels

Fuel Oil FO <150 N/A - 3C1
Diesel Oil DO <60 N/A - 1C2

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 3. Specifications for Materials and Components
Appendix A contains piping class tables for the piping system components required for the Lanjigarh
Alumina Plant 5.0 Mtpa Expansion Project.

In addition to being resistant to the contained process fluid and environmental conditions, all
components utilised in the plant piping systems shall also be considered as being routinely exposed to
caustic liquor in all situations. Accordingly caustic contamination of flash vapours, process condensate and
cooling waters is to be expected. All materials shall therefore be resistant to caustic.

Cast iron material, other than for wafer style butterfly valves or diaphragm valve bodies, shall not be used
for process or service piping components subject to pressure or external piping loads. Grey cast iron shall
not be used for any piping components (due to its brittle nature and inability to withstand impact). Non
ferrous metals such as aluminium, bronze, zinc and brass shall not be used.

Asbestos shall not be used for any application.

3.1 Applicable Specifications

All piping furnished shall comply with the rules and regulations of any Statutory Authority having jurisdiction
and corresponding United States Industry Standards and Codes, whichever is the more stringent. Piping
components shall comply with the requirements of applicable ASME/ASTM standards.

Most pipe components and fittings are specified to common standards and are readily available. Special or
uncommon items, fittings and valves shall be selected from preferred vendors whose products have a
proven track performance in alumina refinery service around the world.

3.2 Piping and Fittings

The following international standards are applicable for pipe and fittings materials and dimensions:

Dimensions: ASME B16.5, B16.9, B16.11, B16.28, B16.21, B16.47

Materials: ASTM A53, A105, A106, A134, A285, A234, A193, A194, A403, A182, A516, A240
Fabricated tees shall only be used where the branch diameter is less than half the header diameter (ie. d b
≤ 0.5 x dh). The branch reinforcement shall fully reinforce the header to it’s nominal wall thickness.
Alternatively weldolets can be used for these branch sizes.

Reducing tees shall be used for all branch sizes greater than half the header diameter.

Seamless pipe is specified for many of the Piping Class Specification sheets in Appendix A. As an
alternative, Electric Resistance Welded (ERW) pipe can be utilised for larger pipe sizes where it fully
complies with the requirements of the design codes above and the requirements of the latest edition of
the standard API 5L ‘Specification for Line Pipe’. It must also meet the carbon content requirements in
Section 3.2.1.

3.2.1 Carbon Steels

The chemical composition of carbon steels to be welded shall meet the following criteria to ensure good
weldability:

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  Carbon content = 0.23% or less
 Manganese content = 1.3% maximum
Carbon equivalent (CE) = 0.43% maximum (by ladle analysis) or 0.45% by check analysis, where CE is
calculated as:

CE = C + Mn/6 + (Cr + Mo + V) / 5 + (Ni + Cu) / 15

3.2.2 Stress Relieving

Carbon steel piping in caustic services may require stress-relieving on cold formed bends and welded
components by post weld heat treatment (PWHT) depending on the free caustic concentration, operating
temperature, frequency of exposure, and the normal operating condition of the pipe (i.e. normally scaled
versus normally clean).

The free caustic concentration (wt%) in the process stream can be calculated using the following formula:

80/106 x Caustic Conc. expressed g[Na2CO3]/l – 80/102 x Alumina Conc. g[Al2O3]/l x 100%

Liquor Density [gpl]

The Caustic Soda Service Chart in Appendix F provides the temperature and free caustic concentration
limits for Caustic Stress Corrosion Cracking (CSCC) susceptibility of carbon steel in the ‘as welded’ and
‘stress relieved’ condition in caustic soda solution. This can be used as a guideline to determine the
requirement for stress relief. (Refer to NACE Standard SP0403-2003 Item No. 21102 for further
information). According to the NACE Standard, caustic soda concentrations greater than 5 wt% pose a
threat of CSCC in carbon steel, however there is still a possibility of cracking failures occurring in services
with lower caustic content at local stress concentrations.

The following piping and equipment should be considered for stress relieving as a minimum:

 All 98% sulphuric acid service piping.

 All 50% caustic piping.
 Steam traced caustic piping.
 All piping requiring stress relief to be compliant with government or statutory standards.
 Caustic cleaning tanks.
 Digester vessels and flash tanks.
 Caustic cleaning piping adjacent to caustic cleaning heat exchangers, tanks and pumps.
 Process lines that are frequently exposed to caustic cleaning liquor as per category 3 or 4
below:
 Category 1: C/wash Exposure < 100 hrs pa & PWHT Not Required
 Category 2: C/wash Exposure > 100 hrs pa & < 1000 hrs pa with significant scale layer
protection à PWHT Not Required.

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  Category 3: C/wash Exposure > 100 hrs pa & < 1000 hrs pa without significant scale layer
protection & PWHT Required.
 Category 4: C/wash Exposure > 1000 hrs pa & PWHT Required
Note: The consideration of scale protection must be exercised with caution (e.g. beware of steam-
addition points and slurry wear points), but it does provide an opportunity to reduce the amount of stress
relieving being specified.

3.2.3 Flange Face Finish

Flange face finish shall be “stock”, which is defined as a surface roughness of Ra 3.2 to 6.3 microns except
for steam service which shall be ‘smooth’ (ie Ra less than 3.2 microns).

3.3 Preferred Pipe Sizes

The following nominal pipe (DN) sizes are preferred for process and service piping in ferrous materials:

15mm; 20mm; 25mm; 40mm; 50mm; 80mm; 100mm; 150mm; 200mm; 250mm; 300mm; 350mm;
400mm; 450mm; 500mm; 600mm; 750mm; 900mm.

Pipe sizes above 900mm may be used in increments of 50mm, however, increments of 150mm are
preferred e.g., 1050mm, 1200mm, 1350mm etc.

At equipment with intermediate size connections, use reducers to match above preferred pipe sizes.

3.4 Valves
Some valves are specified to common standards and are widely available.

Angle slurry valves and control valves are available only from limited sources. These valves are often
manufactured to proprietary (vendor) specifications and dimensions. For these items selection of a
preferred vendor and component range must be confirmed, prior to commencement of Detailed
Engineering.

The table in Appendix C summarises the details of isolation valves required by the piping specifications
presented within this document.

3.4.1 Valve Coding

Valves are referred to in this specification by a 4 to 5 character valve code. The alpha-numeric coding system
is defined in the Project Numbering System, (document number: 311001-00064-000-GE-STD-0001).Note:
Instrument valves are not covered by this specification.

3.4.2 Angle Slurry Valves

Angle slurry valves shall have the following features appropriate to heavy duty service in aggressive
process conditions:

 Cast steel body (ASTM A216 Gr WCB or equivalent).

 Stellite hard-faced disc and seat (Stellite alloy is a cobalt-base alloy with chromium and other

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 metals used for surfaces subject to heavy wear).
 Pressure ratings no less than specified in ANSI/ASME B16.34 up to the piping specification
temperature limit.
 Flange dimensions in accordance with ANSI/ASME B16.5.
 Design permitting “grind-off” of valve seat, to remove encrusted scale formation.
 All DN 300 x 300 angle and bayonet valves and above shall be gearbox operated valves.
Angle or bayonet valves smaller than this shall be manually operated.

These valves are used on Bayer slurries, and all other process applications where significant scale growth
is likely to prevent other valves operating adequately. Major suppliers/manufacturers of angle slurry
valves for the alumina industry include Lunkenheimer, Klein and Poyam.

3.4.3 Gate Valves and Globe Valves (non-slurry)

Gate and globe valves shall comply with the following Standards:

 ANSI B16.34 (Pressure-Temperature ratings)

 ANSI B16.10 (Face to face dimensions)
 ANSI B16.5 (End flange dimensions)
 ASTM A216 WCB or ASTM A336 (Shell material)

As a minimum, Class 150 valves shall have 13% Cr Seats on body and disk, and Class 300 shall have stellite
hard-faced Seats.

All class 800 small bore SW valves shall have full stellite trim (seat and disc).

3.4.4 Concentrated Sulphuric Acid Valves

Valves for Concentrated Sulphuric Acid Service have been specified with stainless steel bodies despite
being installed in carbon steel piping.

3.4.5 Control Valves

Caustic resistance requirement applies equally to all components (including actuators) of control valves
installed in process plant areas. Hence non ferrous metals such as aluminium, brass, zinc, etc shall not be
used.

3.5 Gaskets
Gaskets for all services are nominated in the Piping Class Specification Sheets in Appendix A. Gasket types
and materials of construction shall be confirmed in Detail Engineering.

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 4. Insulation

4.1 General
Insulation in the alumina plant will generally be used on pipework to reduce heat loss or to protect
personnel from contact with hot surfaces.

The following insulation classifications are used:

H Hot temperature for systems operating in the temperature range of +90°C to +350°C.
P Personnel protection insulation/protection designated for equipment and vessels with operating
temperatures in excess of 60°C.
S Steam Traced and insulated for systems operating in the temperature range of +90°C to +350°C.

E Electrically Traced and insulated for systems operating in the temperature range of +90°C to
+350°C.
C Cold temperature insulation designated for systems operating in the temperature range of
-50°C, to +10°C.
0 No insulation.
For heat loss insulation steam valves shall be enclosed in insulation boxes.

Insulation shall not be placed on the following:-

 Valves, flanges and unions of thermally insulated piping.

 Pipework subject to regular NDE.
 Expansion joints and supports for piping and equipment.
 The neck of nozzles up to 300mm long of all flanged connections. When they exceed 300mm,
insulation should be terminated at an adequate distance to allow unrestricted bolt removal.
 Piping heated intermittently, such as blow off piping, air vents, bypass piping at control
valves for heat exchangers except where required for personnel protection.

4.2 Insulation for Personnel Protection

Pipe surfaces operating at temperatures equal to or exceeding 60oC and located within 600 mm horizontally
or 2,200 mm vertically of an access, walkway or work area shall be insulated for personnel protection.

As an alternative to insulation for personal protection, perforated stainless steel sheet may be installed in
lieu of insulation. It has to be sufficiently clear of the pipe or equipment, such that the temperature of the
perforated sheet remains in the range 0C to 60C, when the pipe or equipment is in service and has
reached maximum or minimum operating temperature.

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 4.3 Insulation Materials

4.3.1 General
Insulation materials shall be non-combustible. Materials containing asbestos shall not be used for any
insulation or other purposes.

Recommended materials for insulation of process and utility pipes are:

 Mineral Wool (such as “Rockwool”)

 High Density Fibreglass
 Calcium silicate – for fuel oil or diesel oil lines

Insulation shall be protected with coated steel sheet, or a fabric reinforced mastic. Sheet cladding shall be
secured with stainless steel fasteners or bands. No aluminium fasteners shall be used.

Thermal conductivity of the insulation material shall not exceed the values shown in sections below. The
quality of the insulation shall be such that the dimensional stability of the insulation shall remain
unchanged during handling and in service and shall not deteriorate due to vibration, moisture, caustic or
repeated heating/cooling cycles.

Nominal insulation thicknesses for mineral wool and high density fibreglass are shown in the table in
Appendix D. Insulation thickness for Calcium Silicate, shall be in accordance with manufacturers
recommendations, based on thermal conductivity.

4.3.2 Mineral Wool

Mineral wool shall be suitable for continuous service at temperatures up to 650°C and shall be
manufactured from natural rock or other non-toxic mineral material. For lower temperature steam and
process piping, mineral wool suitable for continuous service at temperatures up to 450°C shall be used.

Mineral wool shall have the following typical properties.

Type Application Thermal Conductivity Density
w/m.k at 100°C kg/m³ (minimum)

Batts and Blanket Vessels, Tanks, 0.05 80

Equipment

Rigid Pipe Sections Steam and Process 0.05 120

Piping

Mineral wool shall be used for insulation of all vessels, tanks, equipment and piping in the refinery and
the power plant.

4.3.3 High Density Fibreglass

High density fibreglass shall be manufactured from glass fibres bonded with a thermo-setting resin and
shall be suitable for continuous service at temperatures up to 350°C.

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 High density fibreglass shall have the following typical properties.
Type Application Thermal Conductivity Density
w/m.k at 100°C kg/m³ (minimum)

Board, Batts and Vessels, Tanks, 0.047 20

Blanket Equipment

Rigid Pipe Sections Steam and Process 0.043 80

Piping (up to 340°C)

4.3.4 Calcium Silicate

Calcium silicate shall be manufactured from hydrous calcium silicate reinforced with a binder. Calcium
silicate shall be suitable for continuous operation at temperatures up to 600°C.

Calcium silicate shall have the following typical properties:

Type Application Thermal Conductivity Density
w/m.k at 100°C kg/m³ (minimum)

Rigid Pipe Sections Fuel Oil 0.056 175

4.3.5 Stainless Steel Mesh

Mesh shall be 25mm hexagonal mesh manufactured from 0.8mm diameter type 304 stainless steel wire.

4.4 Cladding Materials

To protect the insulation the following cladding materials shall be typically used:

Cladding Material Pipework and Vertical vessels over Horizontal vessels and
vessels up to 760mm 760mm OD. pipework over 760mm OD
OD. and for valves and flanges.
Zincalume or 0.6 mm thick flat 0.6 mm thick sheet 1.0 mm thick flat sheet
Colourbond steel sheet (0.47mm for with corrugations
cladding pipes ≤200mm)

Type 304 0.6 mm thick flat 0.6 mm thick sheet 0.6 mm thick flat sheet
Stainless steel sheet with corrugations

Weatherproof High build acrylic

mastic with glass emulsion of trowel
reinforcing cloth grade

Aluminium 0.71 mm thick flat 0.9 mm thick sheet 0.9 mm thick flat sheet
cladding * sheet with corrugations

* Aluminium cladding shall only be used in protected or low caustic exposure areas.

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 5. Pipeline Number System

5.1 Pipeline Designation

Pipelines are numbered using the alpha-numeric coding system that is defined in the Project Numbering
System, (document number: 311001-00064-000-GE-STD-0001).

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 6. Pipe System Specifications
Appendix A includes piping class specifications covering most requirements for the Lanjigarh Alumina
Plant with a low-temperature digestion process (<175ºC). In all cases the potential routing of process
cleaning fluids through Bayer process pipework shall be given proper consideration.

6.1 Pipe Specifications

The following piping classes in Appendix A describe different piping component groups, their Primary
Ratings, and the fluid services for which they are recommended.

The specifications and guidelines are adequate for Basic Engineering, but shall be reviewed and
completed in final form in the detailed design and engineering by the Detail Engineer.

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 Appendix A. Piping Class Specification Sheets

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 SUMMARY OF PIPING CLASSES
Design Code: ASME B31.3
Pipe Piping Corr./Err. Size Design Limits
Class General Service
Numbering Spec Mtrl & Allow. Range Temp. Pressure Service
Description Code
Logic Class Flg Rtng mm DN ºC kPag

1C1 Unassigned

Plain CS. 1C2 Steam, CS 1.5 15-900 0 to 38 1960 High Pressure Steam (10 bar) HPS
SW Sm Bore. Condensate, 150# 100 1760 Low Pressure Steam (6 bar) LPS
Oils 200 1390 High Press Steam Condensate HSC
250 1200 Low Press Steam Condensate LSC
300 1020 Flash Vapour FV
Diesel Oil DO

Plain CS. Sm Br 1C3 Weak Liquors CS 1.5 15-600 0 to 38 1960 Oxalate Slurries OSL
Thrd'd or SW. (< 50 g/L 150# 50 1920 Residue Disposal Liquor RDL
To FLg Rtng. Caustic) 100 1760 Flash Condensate FLC
150 1580 Cleaning Condensate CON
200 1390

Galv. CS 1C4 High Pressure CS 1.5 15-250 0 to 38 1960 Instrument Purging Water IPW
Sm Br Thrd'd Utilities 150# 50 1920 Gland Water GW
To FLg Rtng. (< DN80 100 1760
Galv) 150 1580

Plain CS. 1C5 Plant Utilities CS 1.5 15-900 0 to 120 1000 Plant Air PA
Thrd'd. 150# and Blower Air BA
De-rated Full Instrument Air IA
for large sizes Vacuum Vacuum VC
& B/fly vlvs. Drinking Water DW
Raw Water RW
Filtered Raw Water FRW
Fire Water FW
Hosing (Industrial) Water HW
Alkaline Cooling Water ACW
Non-Alkaline Cooling Water NCW
Anti-Foam Reagent AFR
Drainage Aid DRA
Flocculant FLO
Process Water PW
General Chemical Services GCS
Sump Water SW

Plain CS. BW 1C6 Sulphuric Acid CS 1.5 15-400 0 to 40 1880 Concentrated Sulphuric 98% CSA
Sm & Lg Bore. & Raw Caustic 150# Raw (Fresh) Caustic CAU
To FLg Rtng.

Plain CS. 1C7 Plant Liquors, CS 1.5 50-600 0 to 170 1400 Washer Overflow WO
No SM Bore. Mud Hydrate 150# Pregnant Liquor PL
To FLg Rtng. Slurries Weak Liquor WCL
Hydrate Slurries HSL
Fine Seed Slurries FSL
Hydrate Filtrate FLT
Hot Spent Liquor SLH
Spent Liquor SL
Caustic Cleaning Liquor CCL
Cleaning Liquor Used CLU
Lime Slurry LSL
Flushing Liquor FLI
Tricalcium Aluminate TCA

Plain CS. 1C8 Abrasive CS 5.0 50-600 0 to 38 1960 Bauxite Slurry BSL
No SM Bore. Slurries 150# 50 1920 Mud Slurry MSL
to Flg Rtng. 100 1760 Digestion Feed Slurries DFS
Incr. C.A. 150 1580 Digestion Slurries DSL
200 1390 Blow Off Slurries BOS
Digestion Vent DV

1C9 Unassigned

CS, PE lined. 1C10 Hydrochloric & CS lined Nil 50-250 0 to 60 500 Dilute Sulphuric Acid <10% DSA
No SM Bore. Dilute Sulphuric with PE Hydrochloric Acid 5%-33% HCL
De-rated for Acid 150#
Diaphrgm vlvs.
Plain SS. 1S1 Demineralised SS 1.5 15-250 0 to 38 1580 De-Mineralised Water DMW
SW Sm Bore. Water 150# 50 1530
To FLg Rtng. 100 1320

Plain CS. 3C1 Oils CS 1.5 15-600 0 to 38 5100 Fuel Oil FO

SW Sm Bore. 300# 50 5000
To FLg Rtng. 100 4630
150 4510

Plain CS. 3C2 Mud Disposal CS 1.5 50-500 0 to 38 5100 Residue Mud Slurry RMS
No SM Bore. 300# 50 5000
To FLg Rtng. 100 4630

Plain CS. 3C3 Spent Liquor / CS 1.5 50-500 0 to 38 5100 Spent Liquor SL
No SM Bore. Digestion Feed 300# 50 5000 Digestion Feed Slurry DFS
To FLg Rtng. Slurry 100 4630
160 4480
210 4350

Plain CS. 6C1 Mud Disposal CS 1.5 50-500 0 to 38 10200 Residue Mud Slurry RMS
No SM Bore. 600# 50 10000
To FLg Rtng. 100 9260

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 Appendix B. Piping Branch Chart

311001-00064-000-PE-STD-0001_C Piping Standard

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Appendix C. Valves for Alumina Plant Services

311001-00064-000-PE-STD-0001_C Piping Standard 1

 Valves for Alumina Plant Service

Code Description Size Material Specification Rating End Remarks Typical

Range (DN) Body Trim Details Model
Angle Globe Slurry Valves-
A1F1 900 (Normal) Manual 80x80 to Cast Steel Stellite 150# FLGD-RF 90O angle valve – internal Klein 90O
250x250 disc Lunkenheimer Fig. 603
Poyam 90O V-700
A1F2 900 (Normal) Actuated 300x300 to Cast Steel Stellite 150# FLGD-RF 90O angle valve – internal Klein 90O
900x900 disc Lunkenheimer Fig. 603
Poyam 90O V-700
A1F3 450 (Normal) Manual 80x80 to Cast Steel Stellite 150# FLGD-RF On tank – external disc Klein 45O Tank drain
250x250 Poyam Tank Bottom Valve
A1F4 450 (Normal) Actuated 300x300 to Cast Steel Stellite 150# FLGD-RF Klein 45O Tank drain
500x500 Poyam Tank Bottom Valve
A1F5 SR (Normal) Manual 80x80 to Cast Steel Stellite 150# FLGD-RF SR= Straight Run Klein 45O ‘Y’ pattern
250x250 Poyam straight through V-
700Y & Y body globe
A1F6 SR (Normal) Actuated 300x300 to Cast Steel Stellite 150# FLGD-RF SR= Straight Run Klein 45O ‘Y’ pattern
600x600 Poyam Straight Through V-
700Y & Y body globe
A1F7 900 (Bayonet) Manual 80x80 to Cast Steel Stellite 150# FLGD-RF Klein 90O bayonet
250x250 Lunkenheimer Fig. 604
Poyam 90O V-704
A1F8 900 (Bayonet) Actuated 300x300 to Cast Steel Stellite 150# FLGD-RF Klein 90O bayonet
600x600 Lunkenheimer Fig. 604
Poyam 90O V-704

2
311001-00064-000-PE-STD-0001_C Piping Standard
Code Description Size Material Specification Rating End Remarks Typical
Range (DN) Body Trim Details Model
A1F9 450 (Bayonet) Manual 80x80 to Cast Steel Stellite 150# FLGD-RF Klein 45O Tank drain
250x250 Poyam Tank Bottom Valve
A1F10 450 (Bayonet) Actuated 300x300 to Cast Steel Stellite 150# FLGD-RF Klein 45O Tank drain
450x450 Poyam Tank Bottom Valve
A1F11 3-way 900 Manual 80x80 to Cast Steel Stellite 150# FLGD-RF Lunkenheimer Fig. 605
250x250 Poyam 3 way V-716
A1F12 3-way 900 Actuated 300x300 to Cast Steel Stellite 150# FLGD-RF Lunkenheimer Fig. 605
600x600 Poyam 3 way V-716
A3F1 900 (Normal) Manual 80x80 to Cast Steel Stellite 300# FLGD-RF Lunkenheimer Fig. 603
250x250 Poyam 90O V-701
A3F2 900 (Normal) Actuated 300x300 to Cast Steel Stellite 300# FLGD-RF Lunkenheimer Fig. 603
600x600 Poyam 90O V-701
A3F3 900 (Bayonet) Manual 80x80 to Cast Steel Stellite 300# FLGD-RF Klein 90O bayonet
250x250 Lunkenheimer Fig. 604
Poyam 90O V-712
A3F4 900 (Bayonet) Actuated 300x300 to Cast Steel Stellite 300# FLGD-RF Klein 90O bayonet
600x600 Lunkenheimer Fig. 604
Poyam 90O V-712
A3F5 3-way 900 Manual 80x80 to Cast Steel Stellite 300# FLGD-RF Lunkenheimer Fig. 605
250x250
A3F6 3-way 900 Actuated 300x300 to Cast Steel Stellite 300# FLGD-RF Lunkenheimer Fig. 605
600x600

Gate Valves
G1F1 Rising Spindle 50-750 Cast Steel Steel (13% Cr) 150# FLGD-RF

3
311001-00064-000-PE-STD-0001_C Piping Standard
Code Description Size Material Specification Rating End Remarks Typical
Range (DN) Body Trim Details Model
G1F2 Rising Spindle 50-250 Cast SS 316 SS 150# FLGD-RF
G1F3 Rising Spindle 15-40 Forged SS 316 SS 150# FLGD-RF
G3F1 Rising Spindle 50-600 Forged Steel Stellite 300# FLGD-RF
G6F1 Rising Spindle 50-150 Forged Steel Stellite 600# FLGD-RF
G8S1 Rising Spindle 15-40 Forged Steel Stellite 800# SW
G8S2 Rising Spindle 15-40 Forged SS 316 SS 800# SW
G8T1 Rising Spindle 15-40 Forged Steel Steel (13% Cr) 800# SCR’D
G8U1 Rising Spindle 15-40 Forged Steel Stellite 800# SW/SCR’D

Globe Valves
L1F1 Rising Spindle 50-300 Cast Steel Stellite 150# FLGD-RF
L8S1 Rising Spindle 15-40 Forged Steel Stellite 800# SW
L8T1 Rising Spindle 15-40 Forged Steel Steel (13% Cr) 800# SCR’D
L8U1 Rising Spindle 15-40 Forged Steel Stellite 800# SW/SCR’D

Check Valves
C0F1 Swing Check 50-250 Iron Body – rubber Lined Butyl rubber disc 125# FLGD HCL/Sulphuric Acid Service
C1F1 Swing Check 50-600 Cast Steel Steel (13% Cr) 150# FLGD-RF
C1F2 Lift Check 50-900 Cast Steel Stellite 150# FLGD-RF Angle Slurry Valve Style
C1F3 Lift Check 15-40 Forged Steel Steel (13% Cr) 150# FLGD-RF
C1F4 Lift Check 15-40 Forged SS 316 SS 150# FLGD-RF
C1W1 Wafer Check 50-600 Cast Steel SS 316 150# WAFER

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311001-00064-000-PE-STD-0001_C Piping Standard
Code Description Size Material Specification Rating End Remarks Typical
Range (DN) Body Trim Details Model
C1W2 Wafer Check 50-600 Cast Steel Soft seals 150# WAFER Fuel Oil Compatible Seals
C1W3 Wafer Check 50-600 Cast SS 316 SS 316 150# WAFER
C1W4 Wafer Check 50-600 Cast SS 316 Soft seats 150# WAFER
C3W1 Wafer Check 50-600 Cast Steel Soft seats 300# WAFER Fuel oil compatible seals
C3F1 Swing Check 50-600 Cast Steel SS 316 300# FLGD-RF
C3F2 Lift Check 50-600 Cast Steel Stellite 300# FLGD-RF Angle Slurry Valve Style Klein
C8T1 Lift Check 15-40 Forged Steel Steel (13% Cr) 800# SCR'D
C8S1 Lift Check 15-40 Forged Steel Stellite 800# SW
C8S2 Lift Check 15-40 Forged SS 316 SS 800# SW

Butterfly Valves
F1F1 Flanged type valves 50-500 Carbon steel 28% chrome iron 1400 kPag @ FLGD-FF To Suit 150# Flanges Keystone F638
disc 230OC

F1W1 Wafer type valves 50-500 Heavy Duty Cast Iron SG Iron Disc 1400 kPag @ WAFER To Suit 150# Flanges Keystone Model F2000
120OC

F1W2 Wafer type valves 600-900 Heavy Duty Cast Iron SG Iron Disc 1000 kPag @ WAFER To Suit 150# Flanges Keystone Model F105
120OC
F1W3 Wafer type valves 80-400 Cast Steel 17.4 PH disc 1400 kPag @ WAFER To Suit 150# Flanges Keystone K-Lok F360-325
170OC

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311001-00064-000-PE-STD-0001_C Piping Standard
Code Description Size Material Specification Rating End Remarks Typical
Range (DN) Body Trim Details Model
F1W4 Wafer type valves 50-600 SG Iron SG Iron Disc 1250 kPag @ WAFER To Suit 150# Flanges Keystone F634
230OC

F1W5 Wafer type valves 50-500 Cast Iron SS 316 Disc -40OC to 120OC WAFER To Suit 150# Flanges Keystone F100

F1W6 Wafer type valves 600-900 Cast Iron SS 316 -40OC to 120OC WAFER To Suit 150# Flanges Keystone F1 EPDM seat

F3W1 Wafer type valves 80-400 Carbon steel 316 SS Disc 5100 kPag @ WAFER To Suit 300# Flanges Keystone K-Lok F370-325
40OC, 690 kPag @
230 OC

Ball Valves
B1F1 Carbon Steel 50-250 Cast Steel SS Ball/PTFE 150# FLGD-RF Two piece body
Seats
B1F2 Stainless Steel 50-250 Cast SS 316 SS Ball/PTFE 150# FLGD-RF Two piece body
Seats
B1F3 Carbon Steel 15-40 Forged Steel SS Ball/PTFE 150# FLGD-RF Two piece body
Seats
B3F1 Carbon Steel 50-250 Cast Steel SS Ball/PTFE 300# FLGD-RF Two piece body
Seats
B6F1 Carbon Steel 50-400 Cast Steel SS Ball/PTFE 600# FLGD-RF Two piece body
Seats
B8S1 Carbon steel 15-40 Forged Steel SS Ball/PTFE 800# SW Three piece body
Seats

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311001-00064-000-PE-STD-0001_C Piping Standard
Code Description Size Material Specification Rating End Remarks Typical
Range (DN) Body Trim Details Model
B8T1 Carbon steel 15-40 Forged Steel SS Ball/PTFE 800# SCR’D
Seats
B8U1 Carbon steel 15-40 Forged Steel SS Ball/PTFE 800# SW/SCR’D Three piece body
Seats

Diaphragm Valves
D1F1 Lined 25-250 S.G. Cast Iron – rubber Butyl Rubber 500 kPag @ 60OC FLGD-RF To Suit 150# Flanges
lined Diaphragm

Plug Valves
P3F1 Tapered Plug Valve 100 - 500 Cast Steel ENP plug 300# FLGD-RF
P6F1 Tapered Plug Valve 100 - 500 Cast Steel ENP plug 600# FLGD-RF Tapered Plug Valve

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311001-00064-000-PE-STD-0001_C Piping Standard
 Appendix D. Insulation Thickness

311001-00064-000-PE-STD-0001_C Piping Standard

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 Insulation Thickness

a) Piping
Insulation thickness for piping, based on an ambient temperature of 20C, shall be typically as shown
below. Thicknesses shall be confirmed in detail design.

NOMINAL INSULATION THICKNESS (mm)

NOMINAL PIPE OPERATING TEMPERATURE C (FROM TO)
SIZE
50 100 150 200 250 300 350 400
(mm) 99 149 199 249 299 349 399 499
50 25 25 25 40 40 50 60 60

80 25 25 40 40 50 60 70 70

100 25 25 40 50 60 70 70 70

150 25 25 50 60 70 70 70 70

200 25 25 50 60 70 70 70 80

250 25 25 50 60 70 70 70 80

300 25 25 50 60 70 70 70 80

350 25 25 50 60 70 70 80 90

400 25 25 50 60 70 70 80 90

450 25 25 50 60 70 70 80 90

500 25 25 50 60 70 80 90 100

600 25 40 70 80 80 90 90 110

750 25 40 70 90 100 110 110 130

Flat Surface 25 50 100 120 120 120 120 150

Where heat conservation is not required, insulation shall be applied for personnel protection if
temperature exceeds 60°C. The insulation thickness shall be 25mm minimum.

311001-00064-000-PE-STD-0001_C Piping Standard

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 b) Tanks, Vessels and Heat Exchangers
Insulation thickness on tanks, vessels and heat exchangers shall be typically as shown below.
Thicknesses shall be confirmed in detail design.
Temperature °C Insulation Thickness

Below 75 25mm

75-149 50mm

150-199 75mm

200-249 100mm

250-299 125mm

300-399 150mm

Where heat conservation is not required, insulation shall be applied for personnel protection if the
operating temperature exceeds 60°C. The insulation thickness shall be 25mm minimum.

311001-00064-000-PE-STD-0001_C Piping Standard

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 Appendix E. Instrument Process Connections

311001-00064-000-PE-STD-0001_C Piping Standard

1
 Instrument Process Connections

Instrument Type Service Process Remarks

Connection

Pressure and Differential Pressure

Air, gases, clear non- 15mm NPT with No isolation valves
 Pressure & Differential
scaling liquids 15mm stainless for Safety System
Pressure Transmitters
steel isolation Instruments.
 Pressure & Differential ball valves
Pressure Switches supplied by
piping

Air, gases, clear non- 15mm NPT. No

 Pressure & Differential
scaling liquids isolation valves.
Pressure Gauges
Scaling Fluids, slurries 50mm, flanged.
 Pressure & Differential
No isolation
Pressure Transmitters
valves.
 Pressure & Differential
Pressure Switches

 Pressure & Differential

Pressure Gauges

Temperature
Pipelines ≥ 100mm 50mm flanged, Stand-off includes
 RTD or Thermocouple
with 150mm cladding, if
sensors
stand-off applicable.

Pipelines< 100mm, 15mm screwed, Stand-off includes

 RTD or Thermocouple
warranting < ANSI150 with 50mm cladding, if
sensors
flange rating stand-off applicable.

Pipelines< 100mm, 50mm flanged, Stand-off includes

 RTD or Thermocouple
warranting ≥ ANSI150 with 50mm cladding, if
sensors
flange rating stand-off applicable.

Tanks, vessels 50mm flanged, Stand-off includes

 RTD or Thermocouple
with 150mm cladding, if
sensors
stand-off applicable.

Flowmeters
Magnetic Flowmeters ≤ 200mm warranting < Sized and Wafer
ANSI150 flange rating

311001-00064-000-PE-STD-0001_C Piping Standard

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 Instrument Type Service Process Remarks
Connection

Magnetic Flowmeters ≤ 200mm warranting > Sized and

ANSI150 flange rating Flanged

Magnetic Flowmeters > 200mm Sized and

Flanged

Orifice Plates Refer Instrument and Control Standard for Basic Engineering
04482-J-GS-00-00001

Coriolis Flowmeters Where Applicable Sized and

Flanged

“Annubars” Where Applicable Line Size Flanged

Turbine Flowmeters Where Applicable Sized and

Flanged

Vortex Flowmeters Where Applicable Sized and

Flanged

Level Sensors
Ultrasonic Where Applicable 100mm Flanged

Radar Where Applicable 200mm Flanged

Differential Pressure Where Applicable Refer Pressure and Differential

Transmitter type Pressure Instruments above.

Nucleonic Where Applicable 200mm Flanged

Analytical
Gas Analysers – Where Applicable 200mm Flanged,
twin source and
Carbon Monoxide
detector type

Gas Analysers – Where Applicable 100mm Flanged,

single sample
Methane, Carbon Dioxide, SOX,
point type
OX, NOX

Conductivity, pH, ORP Atmospheric, Nil

immersion type, open
vessel.

311001-00064-000-PE-STD-0001_C Piping Standard

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 Instrument Type Service Process Remarks
Connection

Conductivity, pH, ORP Atmospheric, 50mm Flanged,

immersion type, closed on top
top vessel

Conductivity, pH, ORP Pressurised, immersion 50mm Flanged,

type, closed vessel on top

Conductivity, pH, ORP In Line 50mm Flanged

Where Applicable To suit pipe class

Actuated Valves

311001-00064-000-PE-STD-0001_C Piping Standard

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Appendix F. Caustic Soda Service Chart

Chart showing temperature and concentration limits for CSCC susceptibility of carbon steel in the ‘as
welded’ and ‘stress relieved’ condition in caustic soda solution NaOH.

311001-00064-000-PE-STD-0001_C Piping Standard 1