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ISSUED MASTER SPECIFICATION

Originated by Larry Faught on 17/06/1999

SPECIFICATION DETAILS Status: Issued

Discipline: Design Criteria


Equipment: Design Codes
Title: Shaft And Underground Pipework
Description: Design Code Mines

MASTER SPECIFICATION NUMBER


Specification No: ADC002
Specification Rev No: 01

- ADC002-01~1.doc
ANGLO PLATINUM MANAGEMENT SERVICES (PROPRIETARY) LIMITED
ENGINEERING TECHNOLOGY DIVISION

SPECIFICATION No.: ADC 002

SPECIFICATION TITLE: SHAFT AND UNDERGROUND PIPEWORK

PROJECT TITLE:

BUSINESS UNIT: ALL

AREA: ALL

EQUIPMENT No.: N/A

DISCIPLINE: DESIGN CODE

Rev No Date Description Orig. Project Site Eng. CM&EE M.E.T


Man.
01 10/06/99 Into New Anglo Platinum WvdO - - - KBF
Format

Page 1 of 19
Spec No: ADC 002
__________________________________________________________________________________

Revision Notes
Master Specification No.- ADC 002 Rev.- 01

Site Specification No.- Title.- Shaft And Underground Pipework


Date Rev No Description Revised By
10/06/99 01 Into New Anglo Platinum Format WvdO

Page 2 of 19
Spec No: ADC 002
INDEX

SECTION TITLE

1.0 Definitions

2.0 Design Philosophy

3.0 Design Flow Velocities

4.0 Design Pressures in Systems

5.0 Straight Pipe Design

6.0 Water Hammer

7.0 Design Stress Levels

8.0 Expansion and Contraction

9.0 Flange and Pipe Couplings Design

10.0 Design of Pipe Fittings

11.0 Valves

12.0 Pipe Supports

13.0 Corrosion Protection

14.0 Slurry Handling

ATTACHMENTS:

I Crotch Plate Design

Page 3 of 19
Spec No: ADC 002
1.0 DEFINITIONS

A listing of terms used in ANSI B31.3 is to be found in Section 300.2 of that code. Additional
terms used in this Design Code are listed below.

Clamp Coupling - mechanical pipe coupling of special design comprising a bolted assembly with
internal sealing.

Design Pressure - as defined in ANSI B31.3, Section 301.2.

Fabrication - as defined in ANSI B31.3, Section 300.2.

Gasket Seating Load - the minimum total load required to seat the gasket regardless of internal
pressure.

Head Pressure - the gauge pressure converted from the equivalent head.

Mill Tolerance - deviation of pipe wall thickness from nominal due to normal pipe production.

Minimum Wall Thickness - the least wall thickness resulting from any manufacturing process or
combination of processes which causes thinning.

Mitre Bend - the bend produced by the welding of a number of segments.

Pipe Anchor Support - component or assembly which transfers load of a pipe into a structural
member.

Pipe Guide Support - component or assembly which restricts movement of a pipe to a single
plane.

Solid Drawn Bend - a bend produced by forming a straight length of pipe by induction heating.

Standard Item - proprietary or fabricated pipe, fitting, flange, fastener, gasket valve or accessory
which conforms to Anglo Platinum Standard Drawings and General Specifications.

Static Head - height of column in metres.

Test Pressure - the line or works hydrostatic test pressure as rated in ANSI B31.3, Section 337 or
as agreed to with the manufacturer.

Total Head - the sum of static, friction or water hammer heads. The velocity head is generally of
no consequence except in the calculation of the pump total head which carries a different
definition.

Underground - relating to the shaft and haulages.

Page 4 of 19
Spec No: ADC 002
Viking Johnson Coupling - proprietary standard mechanical pipe coupling supplied under that
name.

Working Pressure - the maximum calculated pressure at any point within the piping system.

2.0 DESIGN PHILOSOPHY

2.1 This Design Code details the minimum requirements for shaft and underground pipework
in the calculation of design pressures and the design of components used on pumped or
gravity feed fluid reticulation.

2.2 The specifications listed in AGS-035 cater generally for standard components.
Non-standard components are to be considered as `Special' and designed within the scope
of this Design Code. In addition, they shall meet the requirements of AGS-035 and are to
be fully detailed on the drawings.

2.3 Unless otherwise stated all branches are to be treated as `Specials' and designed in
accordance with Sections 10.4 and 10.5, or to incorporate the use of standard butt welded
tees.

2.4 For ease of selection, standard drawing JAA 00045103 provides pressure ratings and where
applicable are referred to in the appropriate specifications in AGS-035. The pressure
ratings are design pressures, and have been established from the details contained herein.
The resultant stresses must contain all extraneous forces within the system under
consideration. Superimposed loads which provide additive stresses may require an
appropriate downrating of the design pressure. See Section 7.0.

2.5 In the initial design of a line or subsequent modification to a line, it is important that a full
theoretical analysis of system behaviour is carried out.

2.6 Pipe design and allowable stresses are to be generally in accordance with ANSI B31.3 -
1987 (Refer to Sections 5.0 and 7.0 of this Design Code.)

2.7 Pipework shall be designed for ease of installation and maintenance.

2.8 For the specifications listed in AGS-035, pipework rated above 2MPa shall operate within
an ambient temperature range of minus 8oC to 45oC for chilled water and within 0oC to
45oC for other fluid systems. See Section 8.0.

3.0 DESIGN FLOW VELOCITY

3.1 The maximum flow velocity should not exceed 3.5 m/s. This restriction is based upon
water hammer effects.

3.2 Flow velocities in excess of 3.5 m/s may be considered provided that the theoretical
analysis shows water hammer effects to be within the increased limit stated in Section 7.2.

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3.3 In considering flow velocities of slurries, a balance between the effects of erosion and
settlement should be determined.

4.0 DESIGN PRESSURES IN SYSTEMS

4.1 Units It is generally convenient to determine equivalent pressure heads for static, friction
or water hammer effects and the final total head converted into units of pressure using the
following conversion:

1MPa = 10 bar = 102 metres head.

4.2 Pumped Systems Under normal working conditions the design pressure P consists of the
static head pressure (Ps) plus the friction head (Pf) effective at the pipe position under
consideration.

P = Ps + Pf 1

When water hammer effects are to be considered the design pressure P will consist of the
static head pressure Ps plus the full water hammer pressure Pw effective at the pipe position
under consideration.

P = Ps + Pw 2

The friction head is negligible during the occurrence of water hammer and the pipe
components should be designed for the greater of formula 1 or 2 but modified by
Section 7.0 - Design Stress Levels.

4.3 Gravity Feed Systems

Under free fall conditions and full pipe flow, the total pressure head will consist of the
static head less the friction head. This culminates in a terminal velocity at which point the
two heads are balanced. However, a gravity feed system will normally act as a reservoir
which is tapped off according to needs. In this case the design pressure P is equal to the
static head pressure Ps, alone. If there is any possibility of rapid changes in flow, for
example, due to rapid valve closure, then the design pressure shall include the full water
hammer pressure. In this case formula 2 will apply. In certain cases where valve closure is
against a high static head the generated torque will necessitate gearbox reduction and
therefore lower the magnitude of water hammer effect.

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Spec No: ADC 002
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5.0 STRAIGHT PIPE DESIGN

5.1 The minimum wall thickness (t) of a straight pipe shall be determined from the following
formula:

PDo
t= + A ___________3
2 (SE + Py)

5.2 The design pressure (P) of a straight pipe shall not exceed

P= 2SE (t - A) _____________4
Do - 2y (t - A)

where t = minimum required wall thickness in mm (see Section 5.3)


P = internal design pressure in MPa
Do = outside diameter to pipe in mm
S = maximum allowable stress of material in tension in MPa
E = quality factor (see Section 5.6)
A = extra allowance in mm (see Section 5.4)
y = coefficient (see Section 5.5)

5.3 The minimum pipe wall thickness must take into account the recommended mill tolerance
to which the pipe is subject and therefore shall be reduced accordingly. This tolerance may
be selected from Table 1 below.

TABLE 1 - MILL TOLERANCE ON PIPE WALL THICKNESS

MATERIAL MINUS EXTRA WALL


TOLERANCE THICKNESS

ASTM A106B SMLS 12.5% 12.5%


AP1 5L Grade B SMLS 12.5% 12.5%
AP1 5LX42 upto NB450 12.5% 12.5%
AP1 5LX42 above NB450 10.0% 10.0%
SABS 719 Grade C ERW 8.0% 8.0%

5.4 The extra allowance (A) is to compensate for material removed in threading, grooving or to
make a mechanical joint. In addition the allowance is to provide for corrosion and/or
erosion.

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Spec No: ADC 002
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5.5 The value of y may be taken as 0.4 for both Ferritic and Austenitic steels. This is taken
from the tabulated values of y given in ANSI B31.3 - 1987, Table 304.1.1.

5.6 Quality factor (E) shall be taken from Table 302.3.4 in ANSI B31.3 - 1987. For seamless
pipe the value of E is 1.00 and for electric resistance welded pipe (ERW) E carries a value
of 0.85.

5.7 Pipes and fittings of 200ND and above shall have a nominal wall thickness of not less than
6.0mm.

6.0 WATER HAMMER

6.1 Water hammer is caused by a change in velocity of water in the pipe. The change in
momentum produces a shock pressure rise. This pressure travels along the pipeline as a
pressure wave at approximately the speed of sound through water.

6.2 When a moving column of water is instantaneously brought to rest, an extreme condition
will arise. The effect can be minimised by a relatively gradual retardation of the flow
and/or incorporating a facility for adsorption of the pressure energy.

6.3 In view of the magnitude of the shock pressure being dependent on physical features of the
pipe such as wall thickness, it will be necessary to carry out a full system analysis. In many
cases the upper part of a pump column may display a relatively high pressure rise and, in
addition, may be subject to negative pressures due to a sudden reversal in flow direction of
the pressure wave.

6.4 The following formulae provide a simple method of estimating the pressure due to water
hammer.

Velocity of pressure wave a = 103


_____________ m/s _________5
1 d
x[ + ]
k tE

where K = Bulk modulus of liquid in MPa


(Bulk modulus of water is 2068MPa)

E = Modulus of elasticity of pipe wall in MPa


(E for steel pipe is 206 000 MPa)

d = Internal diameter of pipe in mm

x = Density of liquid in kg/m3

t = Wall thickness of pipe in mm

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Spec No: ADC 002
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aV
Shock pressure head H = (m) ______6
g

where a = velocity of pressure wave from formula 5


V = velocity of liquid through pipe in m/s
g = acceleration due to gravity = 9.8 m/s/s

7.0 DESIGN STRESS LEVELS

7.1 Pipes and fittings The basic allowable Stress(S) shall be one third of the minimum
specified tensile strength of the material. A list of allowable stresses in tension is given in
ANSI B31.3.

7.2 The maximum allowable stress may be increased by 33% in terms of Clause 302.2.4(f) (1a)
of ANSI B31.3 - 1987.

7.3 Allowable stresses in shear, bending and compression as well as any additional local
stresses shall be limited in terms of ANSI B.31.3, Section 302.3.

8.0 EXPANSION AND CONTRACTION

8.1 When a liquid courses through a pipe which has achieved ambient temperature during
installation, a temperature differential may arise causing expansion or contraction of the
pipe.

8.2 The extreme conditions of temperature variations must be allowed for during the structural
analysis.

8.3 Generally, it will be found that resultant pipe stresses due to contraction between anchor
supports will not be additive to the hoop stress but forces should be checked against the
minimum gasket sealing load required in terms of BS 5500, Section 3.8.

8.4 Expansion loads must be checked against buckling.

8.5 Differential contraction between adjacent column lengths above and below an anchor may
impose loading on the anchor which is additive to the load due to the upper column.

8.6 Viking Johnson couplings used on compressed air lines will cater for any variation in pipe
length.

8.7 Rule of thumb temperature gradient is 1oC per 100 metres of shaft depth.

8.8 Bellows type expansion joints are not to be used.

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Spec No: ADC 002
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9.0 FLANGE AND PIPE COUPLINGS DESIGN

9.1 Flanges All flanging shall be selected from the appropriate standard as determined by the
material class specification. Flanges to ANSI B16.5 and BS 4504 shall have raised faces
for use with spiral wound metal laminate gaskets. Flanges to SABS 1123 shall be raised
face for use with ring type compressed asbestos fibre gaskets. Flanges for use with gutta
percha rings have been designed to BS 5500 : 1976 with pipe attachment of the bore and
fillet type as given in figure 21 type 5 of BS 806 : 1975.

9.2 Fasteners All bolts and nuts for flanges to ANSI B16.5 to be designated in imperial sizes
and have class 2A unified coarse threads to ANSI B1.1 - 1974. Material shall be
ASTM A193 grade B7 for high strength bolting. For all other flange applications, bolts and
nuts are to be grade 8.8 and grade 8 respectively and conform to SABS 136 : 1972 with an
acceptance standard of test programme A. Washers shall be through hardened to
SABS 1149.

9.3 Gaskets All gaskets for raised face flanges to ANSI B16.5 and BS 4504 shall be spiral
wound metal laminate type CG or CGI and be selected for use with the appropriate flanging
table. Materials of construction are to be 4.4 thick compressed asbestos fibre filler with
plated low carbon steel metal windings. Gaskets for sludge duties shall have both an outer
and inner ring (type CGI). Gaskets for all other duties shall have an outer location ring
only (type CG). Gaskets for use with grooved flanges shall be made from gutta percha with
a hardness of 70 shore A.

9.4 Clamp Couplings Design Shall be manufactured from steel with a carbon content not
exceeding 0.25%. The mechanical properties of the material shall not be less than 95% of
that of the specified pipe material. The design and manufacture of Viking Johnson type
high pressure couplings shall be such that the seals will not extrude through the flanges and
each coupling shall have a removable centre register which shall have adequate sealing
against the pressure.

9.5 Torque Tightening Values for flange bolts are to be determined to effect sealing loads
which comply with BS 5500, Section 3.8 and these values are to be quoted on the design
drawings.

9.6 Surface Finish for Flanges It is recommended that the surface finish for sealing surfaces in
Ra values is as follows:

a) Spiral wound gaskets - gramophone finish between 3.2 and 12.5 micrometres.

b) Ring type and flat face (CAF) - gramophone finish between 12.5 and
25 micrometres.

c) Gutta Percha - between 0.8 and 1.6 micrometres.

10.0 DESIGN OF PIPE FITTINGS

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Spec No: ADC 002
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10.1 Pipe Bend Design The minimum wall thickness of a pipe bend shall be as for the straight
pipe and subject to the design stress levels in Section 7.0.

10.2 Solid Drawn Pipe Bends Shall be formed by the induction heating pipe bending method or
any other method acceptable to the Engineer which provides a bend substantially free of
cracks when inspected by the liquid penetrant crack detection method.

The maximum ovality measured on the outside diameter and expressed as


(Do (max) - Do (min)) / Do (nominal), shall not exceed 8%.

The ratio of the mean bend radius to the outer diameter of the pipe shall not be less than 3.
Refer to material specifications in AGS-035. Seamless pipe shall be used for hot formed
bends and the bends shall be treated as special and fully detailed on the design drawing.

10.3 Mitre Bends Mitre (including Duckfoot) bends shall not be used above a pressure of
7.5 MPa, and the angle spanned by any one segment shall not be more than 30o.

10.4 Reinforcement Local weakness caused by pipe branch openings in the main pipe shall be
re-inforced in the weakened area, unless butt-welding tees of suitable rating are used.

Reinforcement design shall be based on the `area replacement' method to the requirements
of ANSI B31.3 - 1987, Clause 304.3. In the selection of the method of reinforcement, due
consideration must be given to both the flow effect and fabrication. The decending order of
preference is:

(a) Integral Reinforcement

This is the preferred method and shall be obtained by increase of main leg and
branch leg pipe thickness.

This method is mandatory where the ratio of the branch pipe nominal diameter to
main pipe nominal diameter is equal to or exceeds 0,75.

(b) Compensating Reinforcement Pad

The pad shall be circular in plan view, formed to the radius of the pipe and located
symmetrically about the branch pipe axis. Adjacent pads shall not be overlaid.

The design stress in the reinforcement should not be greater than the hoop stress used
in the design of the pipe.

(c) Crotch Plates

Where methods a) and b) prove to be impractical the use of crotch plates may be
considered. This method is suitable both for tees and laterals but within the
restrictions of Section 10.5. The lower order of preference is based upon the larger
area of reinforcement being prone to corrosive attack. See Appendix A for design of
plates.

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Spec No: ADC 002
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10.5 Branch Pipe/Main Pipe Joint Configuration

The angle between the branch pipe and the main pipe shall not be less than 60 o. If it is
unavoidable then the angle can be decreased to 45o but the ratio of the nominal branch
diameter to the nominal main pipe diameter must then be less than 0,5.

The distance between centre lines of adjacent branches in the same pipe shall not be less
than twice their mean diameter. A pipe shall not have two diametrically opposite openings.
Multiple branches should be spaced such that their individual reinforcement zones do not
overlap.

10.6 Butt Welding Pipe Fittings

Fittings for butt welding shall be to BS 1640 : Part 1 : 1962 or ASA B16.9. The material
shall be seamless and to grade WPB. All flanged fittings shall have a pipe extension
welded to each end; the pipe material having the same properties and wall thickness as the
fitting. The minimum distance between the butt weld and the back of the flange shall be
with a minimum of 75mm.

End preparation and matching of unequal wall thicknesses shall be in accordance with
BS 1640 : Part 1, Section 2 or equivalent.

10.7 Forged Fittings for Socket Welding

Fittings for socket welding shall be to BS 3799 or ASA B16.11. Forged fittings for
screwed lines shall be BS 3799 and screwed BSP.

11.0 VALVES

11.1 Valves shall be selected for the specific duty, rating and operation required.

11.2 In order to ensure a `fitness for purpose' the expertise of the valve supplier must be sought
and coupled with past experience gained from similar applications.

11.3 Information to be given to the valve supplier shall include, but not be limited to:

(a) Maximum differential working pressure plus shock pressure.

(b) Full details of medium to be carried including corrosiveness, abrasion, particulate


matter, line transport velocity and volume of flow.

(c) Environmental conditions.

(d) Duty, e.g. isolation, regulating pressure control, together with closure time required.

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Spec No: ADC 002
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(e) Type of control, i.e. manual, automatic (local or remote) and any limitations of
access.

(f) Limitations of space for determining gearbox/actuator/handwheel orientation.

(g) Flanging table. This may be restricted to the supplier's current patterns position.

(h) Line position and adjacent features. In certain cases full particulars of the line may
be required in order to carry out a flow analysis.

11.4 The flatness of flanges which mate with those of the valves is important in order that no
undue strains are induced which may adversely affect the valve performance and operation.
Support of the valve may be necessary for the same reasons.

11.5 Where throttling is required, the maximum recommended differential pressure of the valve
must be observed. An excessive pressure recovery will cause cavitation and lead to sudden
wear of the seat area.

11.6 Consideration must be given to straining out particulate matter which could prevent correct
seating. Under high pressure conditions wire drawing may occur with subsequent damage
to the seat.

12.0 PIPE SUPPORTS

12.1 Vertical columns shall be anchored at intervals not exceeding 100 metres. This is primarily
to facilitate jacking of the column for maintenance purposes and, in addition, to limit the
moments placed on the anchor bolts.

Although not mandatory the following guide to selection and spacing of supports may be
used.

a) Screwed piping - gripped type `U' bolt or strap every 5 metres.

b) Flanged pipe 50NB to 250NB - anchored every 100 metres together with
non-gripped `U' bolts or straps every 5 - 10 metres.

c) Flanged pipe 300NB and above - anchored not more than every 50 metres together
with non-gripped `U' bolts or straps every 5 metres.

d) Coupled pipes - anchored at least every pipe length.

12.2 Refer to Section 8.0 for loadings due to expansion or contraction.

12.3 All continuous columns other than screwed or coupled pipes shall be provided with a
duckfoot support designed to accept vertical loads from both the full liquid column and the
bottom section from the last anchor. In addition the duckfoot must be designed to accept

Page 13 of 19
Spec No: ADC 002
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horizontal forces due to pressure loading, water hammer and contraction/expansion in the
piping along the level.

12.4 Pipe supports along levels shall allow for normal flexibility design and shall be positioned
so that no undue loads are imposed on joints, valves or pumps. Heavy valves shall be
suitably supported in order to restrict loadings for reasons stated in Section 11.4.

12.5 Forces due to water hammer will be imposed on each support and will generally be minor
at the shaft anchor but could be significant on the duckfoot.

12.6 Anchor supports shall be designed to accept both upper column loading and the suspended
load from the lower section of the column. This is notwithstanding any additional loads
that may be present.

13.0 CORROSION PROTECTION

13.1 Corrosion Protection Philosophy

The applied corrosion protection shall be based on cost effectiveness, resistance towards
both corrosion and abrasion in shaft and haulage conditions and protection against
mechanical damage.

The selected corrosion protection method must also provide for long term protection as, in
general, the rectification of corrosion protection systems or the application of new systems
in both the shaft and haulage conditions is costly and ineffective on account of the harsh
prevailing conditions.

13.2 Shaft Applications

13.2.1 Columns

All shaft columns shall be hot dip galvanised in accordance with SABS 763 and
Anglo Platinum AGS-030.

In lower, more corrosive areas in the shaft use shall be made of an additional
epoxy coating (termed Duplex coating) and reference shall be made to Design
Code ADC-001 to ascertain the extent of the Duplex coating.

For sludge columns or where highly abrasive slurries are involved, the
application of the Duplex coating to the internal surfaces can be considered.
Reference should be made to Design Code ADC-001 for more information in
this regard.

13.2.2 Flanges

Flanges shall be hot dip galvanised in accordance with SABS 763 and Anglo
Platinum AGS-030 as a minimum degree of corrosion protection. Use of the

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Spec No: ADC 002
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Duplex coating shall be dependent on the location within the shaft and reference
shall be made to Design Code ADC-001 for this purpose.

Where machining of the sealing face of the flange is required, two options are
available:

a) Hot dip galvanise the flanges after machining, followed by removal of the
zinc coating by means of a gas flame and brushing, wiping, so as to restore
the machined face.

b) Machining after hot dip galvanising. This may be achieved by use of Sibex
equipment or similar.

In either case the requisite surface finish given in Section 9.6 is to be maintained.

13.2.3 Fasteners

All fasteners shall be hot dip galvanised in accordance with SABS 763 and
Anglo Platinum AGS-030. Hot dip galvanising by means of a centrifuge only
shall be used in order to control the coating thickness. The coating thickness
shall be 50 micrometres minimum and 90 micrometres maximum.

The galvaniser shall ensure that the galvanising process is suitably modified to
avoid excessively thick coatings when high silicon content steels are used.

Cold formed bolt heads shall be suitably heat treated to avoid strain age
embrittlement.

Nuts shall be over tapped in accordance with SABS 763.

13.2.4 Locking Bolts

Locking bolts which contain non-metallic inserts (e.g. Nylock) shall not be used
as they cannot be hot dip galvanised.

13.2.5 Brackets

All brackets shall be hot dip galvanised in accordance with SABS 763 and AGS
030 as a minimum form of protection. The use of the Duplex coating shall be
dependent on the location of the brackets within the shaft and reference shall be
made to Design Code ADC-001 for this purpose.

13.3 Haulage Applications

For haulage piping, use can be made of either hot dip galvanising or coated mild steel. For
coated mild steel, PS 114 of Anglo Platinum AGS-011 shall be used with care being taken
to repair any damaged areas.

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Alternative materials to protected mild steel can also be considered, e.g. 3CR12,
304 stainless steel, GRP, HDPE, etc., provided the following factors are considered:

(i) Cost effectiveness.


(ii) Special design, fabrication and testing procedures are carefully defined.
(iii) Bi-metallic contact is avoided (eg. between piping and supports, flanges,
etc).
(iv) Non flammability of materials, with respect to non metallic materials.

14.0 SLURRY HANDLING

14.1 The design of a reliable slurry piping system can only be based upon the full knowledge of
a number of variable factors. To base the design on experience gained from a similar
installation may be somewhat tenuous as the characteristics on which the original design
was based may have varied over the lifespan due to operational requirements. It is
therefore essential that the system is designed upon sound principles at the outset.

14.2 Factors influencing the design include:

a) Type of pumping to be used.

b) Character of slurry, i.e. whether homogeneous or heterogeneous.

c) The resulting effect of b) on the abrasiveness of the slurry.

d) The corrosiveness of the slurry.

14.3 In turn the above will influence the considerations to be given to the detail design of the
system such as:

a) Pressure pulse fluctuations of a positive displacement pump producing


cyclic fatigue stresses.

b) Internal streamlining to minimise eddying and variations in flow velocity.

c) Suction piping.

d) Drain and flushing points.

e) Ease of replacement for areas of maximum wear.

f) Valve selection.

14.4 A comprehensive publication dealing with slurry systems which may be consulted is
"Slurry Pipeline Transportation" by E. J. Wasp.

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ATTACHMENT I - CROTCH PLATE DESIGN

Figures 3 to 5 are design charts for external crotch plates and are expressed in dimensionless
parameters.

The method of design using the charts is as follows:

(1) Calculate Pd1/ft knowing the maximum internal pressure P, the main pipe diameter d 1, the
permissible plate stress f and an assumed plate thickness t.

(2) Read off from Fig. 3 the crotch plate width expressed in terms of the main pipe diameter d1;
b1 and c1 are the crotch plate widths for a 90 o lateral with the same diameter as the main
pipe.

(3) If the branch is at an angle to the barrel, or the diameters are unequal, read K b and Kc from
Fig. 5 and correct the crotch plate width by multiplying b1 by Kb and c1 by Kc.

(4) The plate widths are now b = d1(b1/d1)Kb and c = d1(c1/d1)Kc.

(5) Read the plate top depth ratio a/d1 corresponding to b/d1 or c/d1 and the angle of the lateral
from Fig. 4 and hence calculate a, the top depth of each plate.

(6) Check whether either plate width is greater than 30 times the plate thickness. If so, the
plate is liable to buckle, so increase the plate thickness and try again. The shape and weight
of plates could be optimized by trial.

Fig. 1 Lateral with external crotch plates. Fig. 2 External crotch plates.

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Fig. 3 Crotch plate side width. Fig. 4 Crotch plate top depth.

The shape of the plate should then be drawn for fabrication by developing the line of intersection of
the pipes.

Double plates will be fillet welded together at the intersection point, or if thin enough, may be bent to
follow the intersection of the branch and the barrel.

For large installations a third plate may be required, placed at right angles to the axis of the main pipe
(See Fig. 1).

Whether crotch plates should be used at all is also a matter of judgement. It is advised that crotch
plates are used if the internal design pressure P is greater than yt 1?o/135Gd2 where G is the factor of
safety, t1 is the wall thickness of the main pipe, d 2 is the diameter of the branch pipe and ? is the angle
between the axis of the branch pipe and barrel. y is yield stress.

Three Plate Design

The preceding nomograph section has covered the design of two-plate wye branches without touching
on a three-plate design because of its similarity to the two-plate. The function of the a third plate is to
act like a clamp in holding down the deflection of the two main plates. In doing so, it accepts part of
the stresses of the other plates and permits a smaller design. This decrease in the depths of the two
main plates is small enough to make it practical simply to add third plate to a two-plate design. The
additional plate should be considered a means of holding down the deflection at the junction of the
plates. The two factors which dictate the use of a third plate are diameter of pipe and internal pressure.
When both of these are above a certain limit, a ring plate can be used advantageously. It is
recommended that these limits be placed at 1500ND and 2MPa. If either of these factors is below the
limit, the designer should be allowed to choose a third plate. If a third plate is desired as an addition to
the two-plate design, its size should be dictated by the top depth (a). Because the other two plates are
flush with the inside surface of the pipe, however, the shell plate thickness, plus clearance, should be
subtracted from the top depth. This dimension should be constant thoughout, and the plate should be
placed at right angles to the axis of the pipe, giving it a half-ring shape. Its thickness should equal the
smaller of the main plates.

Page 18 of 19
Spec No: ADC 002
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Fig. 5 Effect of lateral diameter and angle on crotch plate size.

Page 19 of 19
Spec No: ADC 002

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