Veer Aluminium Gas Pipeline

Veer Aluminium Gas Pipeline Design and Installation

Introduction:

Veer Aluminium is a South African company that specializes in aluminium extrusion with exceptional quality, short lead times, and unmatched reliability. They have embarked on a major expansion of the manufacturing facility in Olifantsfontein. Through a dedicated effort of their team, they have selected and sourced natural gas as a key component of their energy mix at their new facility.

Ayogas has been appointed by Veer Aluminium to design, install and commission their internal natural gas pipeline. The process flow calculations and pipe size design were included in the Ayogas design. Provision was made for the site’s 15 points of use which include 2 x 40t melting furnaces amongst others.

Scope of the Project – Ayogas:

The internal gas line for Veer Aluminium was designed for a max operating pressure of 6 Bar. The main pipe size is 200mm effectively making this a Category 2 installation as per SANS 347. Ayogas employed a professional engineer, draughtsperson and an AIA on the project to adhere to the requirements of the Pressure Equipment Regulations and SANS 347. The category of installation also necessitated the use of coded welders, an AIA approved welding procedure and thorough weld maps and quality control. Phase 1 of the gas line has already been completed, pressure tested, signed off and a COC issued.

The gas installation consists of the following:

294m x 8”; 200m x 6” & 272m x 4” #40 Seamless Steel Pipe
15 x 4” Flanged Ball Valve Service Points (c/w SAGA Permits)
Design & Manufacturing Code – Asme B31.8 (2020)
Sans 347 Hazard Category – Cat II
Sans 347 Conformity Assessment Module – Module A2
Manufacturer – Ayogas (Pty) Ltd
Approved Inspection Authority – Indserve Cc | Per 038
Design Pressure – 700 kPa
Corrosion allowance – 1.0 mm
Fluid medium – Natural Gas
Pressure test procedure – Pneumatic (Test pressure – 770 kPa)
Material specification – SA-106 GR.B; SA-105 n; SA-234 WPB
Non-destructive testing – 10% RT
Welding Procedure and Qualification of Coded Welders
Professional Design and AIA (Authorised Inspection Authority)
SANS 329 & SANS 347 compliant system & COC
Testing and commissioning
Data Pack to Client

The outcome:

The first phase of the project was completed on schedule and within budget. The gas installation has been designed and constructed in such a manner to enable the next phases and future expansion without affecting current operations.