— EG Ger fo SSBB INSULATING JOINTS FOR GAS PIEPELINES Quality, testing and arrangement of insulating joints in gas ‘peliCONTENTS Preface 1. Scope 2 Functions and applications of insulating joints 3. Terminology 4, General (nsulating joints for operating pressures of more than 16 bar Insulating joints for operating pressures of over 4 bar up to 18 ber Insuleting joints for operating pressures of up to 4 ber 8. Barrier ftings with integrated insulating joints for operating pressures of up to 4 bar 9. Insulting joints for control- and meesuring lines 10, Ready-to-it insulating flange joints 11. Insulating flange pairs 13 14 1624 22 23 24 oe Preface ‘This technical recommendation for he manufacture, testing and the installation of electrical insulating joints in gas pipelines made of metal (pipeline and plant) has been prepared by CEOCOR section A in cooperation with competent experts. Scope This recommendation applies for quality, manufacture, testing and installation of factory- produced insulating jomnts in pipelines and piant as well as those that are integrated in barriers and suitable for gases of the categories 2 and 3 according to EN 437, This recommendation does not deal with questions of guarentee and oher commercial aspects. Functions and applications of insulating joints An Insulating joint is a non-conductive pipe connection that interrupts the linear electrical conductivity of 2 metal pipeline. The insulating joint is used for demareation of cathodic protection areas - interruption of pipe current fows (e.g. stray currents, geomagnetic currents) local limitation of inductive influences - shock protection prevention of the gas pipeline becorning an earth line separation of meta! pipelines made of different material or covered with different sheaths. ‘The installation of insuisting jeints may be required in the following cases: in metal pipefines for the electrical separation of fine sections - in gas pressure regulators and measuring systems as well as in compressor plants where the metal lines enter and leave - in valve and scraper stations, ifthese have to be separated electrically from the pipeline - in contro! and measuring lines, if these adversely effect the cathodically protected part of the installation ~ buried house connection lines and supply pipes made of metal Insulating parts are preferred to insulating flange joints, because the former can't be removed later and therefore prevent more reliabiy their mechanic and electrical qualities,3 Terminology a4 aad 242 44 32 33 34 35 38 3.6.1 36.2 Electrical insulting joint Insulating joint The insulating joint is @ factory-produced, ready-to-fit pipeline element, that can't be taken apart and that serves for the interruption of the electric linear conductivity of a pipetine. Ready-to-ft insulating flange joint A ready-to-fit insulating flange joint is a fectory-produced, ready-to-fi flange joint that functions as an insulating joint due to is special construction, Insulating flange pair ‘An insulating flange psir is 2 factory-produced insulating flange joint that must be taken apart ‘when itis welded into the gas pipeline. Barrier fitting with integrated insulating joint A barrier fiting with integrated insulating joint is a structurel component of a pipeline that unites the function of the barrier fiting end the insulting joint, Creep distance A creep cistance is the shortest distance on the surface of insulating parts between the ‘conducting pars. Air gap ‘An alr gap is the shortest distance in the air between conducting parts. Testralternating voltage A test-allernating voltage Is the effective value of an altemating voltage apptied during the test period at a cortain frequency. Gap section A gap section is the smallest thickness of the insulating material between the parts that have tobe separated electrically. ‘Overvoltage protection device ‘An overvaltage protection device is an installation for the protection of the electric equipment and systems agains! inadmissibie high overvoltage. Spark gap A sparkgap is the distance between electrically conducting parts that is bridged by ares in case of electric fash over. ‘Spark bridgeeG ‘A spark bridge is an overvoltage protection device integrated in the insulating joint. 4 General 4.4 The factory must produce the insulating joints so that they are ready to fit and that they conform t0 the technical requirements for construction, quality and pneumatic test for the proposed installation 42 The meteriel used(seels, plastic, laminated fabric rings, etc) must be resistant to gases of the category 2 and 3 according to EN 437. 4.3 Insulating joints must be designed so that they do not fose their effectiveness if imperviousness is tested or moisture penetrates. 4.4 In order to avoid the danger of inacmissible temperature rise of the insulating joints during ‘welding, the open pipe ends of ready-to-ft insulating joints must not be below the following minis 400 mm when applying SMAW (electronic welding) 250 mm when appiying OAW (autogenic welding) 4.5 Inorder to ensure that the insulating joints can be welded into the pipelines, the stee! quality of the open pipe ends must correspond to the regulations according to EN 10208-2. 46 When welding the insulating joints by electric welding, the earth contact must be fixed exactly. Ifthe earth contact is fxed on the wrong position (welding current might flow over the insulating joint), the insulating joint can be destroyed. 5 insulating joints for operating pressures of more than 16 bar 51 General 5.4.1 For every type of construction or for @ modification of the original construction plan, a prototype testing by an authorised testing agency (accrecited testing laboratory) must be proved. 5.4.2 The components of insulating joints must be tested. The test resulls must be proved in ‘writing end presented to the customer. 5.4.3 insulating joints destined for installation into gas pipetines made of ste! must be designed to resist the nominal pressure of the line end must correspond to EN 10208-2, 5.1.4 When producing the insulating joints @ quality status corresponding to EN 729-1 and EN 729- 3 must be cbserved while welding, 5.1.5 When the test pressure of the line does not exceed the test pressure of the insulating joint the latter can also be installed into the line before the pressure of this line is tested,52 5.24 522 523 524 625 626 627 528 529 5.2.10 8241 8.2.42 52.43 Ge Construction requirements, ‘The calculation of the parts under pressure must be based on @ load factor of at least S = 18. ‘The customer has to specity the desired stee! qually of the welding ends. The maximum CEV (carbon equivalent) mus! correspond to the regulations eocording EN 10208-2. The welding ends of insulating joints have to be designed corresponding to EN 10208-1, table 10. ‘The insulating joints must be designed for a minimum temperature range of the medium of - 40°C up to +80°C. Differing temperatures have to be specified by the customer. In order to exclude damage to the inner seal parts ofthe insulating joints owing to lightning or high tension interactions, appropriate construction measures must ensure thet @ possible electrical flash over can not occur inside the pipeline, An electrcai flash over must not affect the imperviousness of the insulating joint. In order to protect an insulating joint against fash overs ewing to lightning and high tenston interactions, an overvoltage protection device with @ maximum operating impuise voltage according to the half of the test voltage (withstand alternating voltage) of the insuteting joint and with a leakage impulse current of 50 kA (waveform 10/350 us coresponding to IEC 1024-1 and IEC 1312-1) must be provide. ‘The overvoltage protection device should be fixed directly on the insulating joint (maximum loop length 300 mm). In special cases the overvoltage protection device can be fixed above ground at an accessible measuring point if the lenglhened line feed is designed with the lowest impedence possisle corresponding to the determined length of the loop. To be efficient the overvoltage protection device must be connected with the insulating joint with a maximum connection inductence of 0,3 uH. This can be cbtained by using @ maximum loop length of 300 mm or other line feeds with low impedance, e.g. co-axial cables, drilled lines, etc, whose total inductance does not exceed 0,3 uH and is resistant to high lightning current {at least 18 mer Cu according to IEC 1024-1} Hf the insutating joint is placed in 2a explosive gas atmosphere @ surge arrester with the respective licensing corresponding to EN 80014 must be used. In this c2se it is important to ‘consider that the connection on the insulating joint aiso has to be expiosion proof. ‘When using insulating joints with an integrated spark bridge the corresponding proofs according to §,2.6, .2.6 and 5.2.8 must be presented - except the demand that the operating voltage must not exceed haif ofthe test vollage. Only insuiating jcints that are welded or constructed in an other appropriate way can be used, Pressed types similar to those in fig, 3 are not permissible in this pressure range. Appropriate material (e.g. composite coating materiel on the basis of phenonol-resin strengthened with paper or reinforced paper) serves as insulating material |n piggabte lines the inside diameter of the insulating ring must have the seme size or must be up to at most 3mm smalier than the inside diameter of the insulating joint. In non-piggable lines the inside diameter of the insulating ring can be up to 10% smaller than the inside diameter of the insulating joint.8.2.14 52.15 52.18 5247 5218 5.2.19 5.2.20 5221 92.22 53 63.4 532 533 Ge Crring-seals with regular roundings are recommended as sealing material. The sealing rings must be placed on appropriate ctop-shaped grooves or grooves in another shape that are found in ihe metalic malerial Underground insulating joints must suitably be coated or wrapped. Above ground insulating joints may be coated with a non-conductive material (beware of shock protection!) ‘The external coating and primer must be compatibie. Factory-coated insulating joints with welding ends must have en open, uncoated pipe end of at least 160 mm. The exterior coating of insulating joints with flange connection must, corresponding to fig. 1, reach up to the flange; the sealing surface of the flange s well as the bearing surface of the serew joints must be free of any coating. The insulating joints must also be coated inside, in order to prevent an electrical bridge caused by a foreign element inside the insulating joint. This interior coating can for instance be achieved by applying @ PE- or EP.coating (preceding sandblasting is absolutely Necessary) or @ two-component high-build coating. The coating thickness must be at least 0,4 mm and abrasion-resistant, ‘The inner side must be coated as far as the sealing chamber or continuously by passing the insulating ring (fig. 1) and as far as 2 distance of 150 mm from both weiding ends. In insulating joints with fange connection the interior coating must reach on both sides up to the inner edge of the flange. Each insulating joint must be merked on a visible place with the following information: + make ~ type designation ~ serie! number or acceptance number = nominai width (DN) ~ homninal pressure (PN) steel quality of the pipe ends ~ mark of the testing agency or ofthe tester. Test coneitions and tests ‘Strength analysis Jn the factory each insulating joint must pass a water pressure test catried out under a pressure of et feast 15 times the nominal pressure for al least § minutes. inthis test the ends 2re lo be closed so that the axes of the insulating joint are not under pressure. The procedure of the strength enalysis can be agreed between the customer and the manufacturer. Leakage test After the woter pressure test, 2 leakage test must be carried out wit air under a pressure of 5 bar for a period of at least 10 minutes before seltpoiishing. In this test leakage is not permissible Electrical testeG Each insulating joint must be tested in cry conditions with a minimum voltage of 6000 Y-(S0Hz) for 1 minute, During this test there must not eccur @ corona discharge or an insulation failure, ‘The maximum leakage current (at 6000 Volt, 80 Hz) depends on the capaciy of the relevant insulating joint (type, size, nominal width, pressure stege, etc.). For the secommended values for the maximum leakage cutrent see table 1. Table 1: Recommended values for the maximum leakage current (composed of ohmic ‘nd capacitive current) = PNT, SPNTO = PN 100 Sma SON 800 = DN 400 SON 200 T0mA > DN 800 > DN 400 > DNZ00 SDN 1200 SDN 800 = DN 600 After the water pressure test the insulation resistance of the dry insulating joint must be at least 0,1 Mr: when measuring with a direct voltage of at teast 500 V. After a drying Period of 5 hours at roont temperature @ value of at least 100 M2 must be achieved. 534 — Exterior coatings made in the factory must pass a non-porosity test with an alternating voltage of 25 000 V. 53.5 The results of the non-poresity test of the exterior coating can also be integrated in the test certificate ofthe insulating joint. 5.3.8 The conformity with the desired qualties and the data corresponding to 5.2.22 have to be ttested according to EN 10204 with an acceptance test certificate 3.1.A or 3.7.C. 5.3.7 When using steel qualities with a yield point of > 360 Nimm?, for the open pipe ends an acceptance test certificate 3.1.A or 3.1.C according to EN 10204 is also required for the pipe material (see prEN 1594) 6 _ Insulating joints for operating pressures of over 4 bar up to 16 bar 61 General 8.1.1 For every type of construction or for 2 modification of the original construction plan, a prototype testing by an authorised testing agency (acoredited testing laboratory) must be proved. 6.1.2 The components of the insulating joint must be tested. The test resulls must be proved in writing end presented to the customer. 5.1.3 Insulating joints destined for installation into gas pipelines made of steel must de desicned to resist the nominal pressure of the iine and must correspond to EN 702081. 6.1.4 When producing the insulating joints a quality status cormesponcing to EN 729-1 and EN 729-2 must be observed while welding62 6.24 622 623 624 625 626 627 628 629 6.2.10 62.11 62.12 6213 Ge When the test pressure of the line does not exceed the lest pressure of the insulating joint the latter can alsa be installed into the line before the pressure of this line is tested, Construction requirements ‘The calculation of the parts under pressure must be based on a load factor of al least S = 18. ‘The customer has to specify the desired steel quality of the welding ends. The maximum CEV (carbon equivalent) must correspond to the regulations according to EN 10208-2. Generally, the welding ends of insulating joints have to be designed corresponding io EN 10208-2, table 10. ‘The insulating joints must be designed for a minimum temperature range of the medium of - 10°C up to +80°C. Diflering temperatures have lo be specified by the customer. In order to exclude damage to the inner seai parts of the insulating joints owing to lightning or high tension interactions, appropriate construction measures must ensure that a possible electrical flash over can not occur inside the pipeline, An electrical fash over must not affect the Imperviousness of the insulating joint, {0 order to protect an insulating joint against flash overs owing to lightning and high tension interactions an overvoltage protection device with a maximum operating impulse voltage according to haff of the test voltage (withstand alternating voltage) of the insulating joint and with a leakage impulse current of 50 kA (waveform 10/350 4s corresponding to IEC 1024-1 and IEC 1312-1) must be provided. ‘The overvoltage protection device should be fixed directly on the insulating joint (maximum Toop length 300 mm). in special cases the overvcitage protection device can be fixed above ground at an accessible measuring point if the lengthened line feed is designed with the lowest impedance possible corresponding to the determined length of the loop. To be efficient the overvottage protection device must be connected with the Insulating jcint with @ maximum connection inductance of 0,3 ul. This can be obtained by using a maximum loop length of 300 mm or ether line feeds with low impedance, e.g. co-axial cables, died lines. etc, whose total inductance does nat exceed 0.3 j1H and is resistant to high lightning current (et least 18 mm® Cu according to IEC 1024-*) If the insulating joint 's placed in an explosive gas atmosphere a surge errester with the respective licensing corresponding to EN 50014 must be used, In this case it is important to consider that the connection on the insulating joint also has to be explosion proof, When using insulating joints with an integrated spark bridge the corresponding proofs according to 6.2.5, 6.2.6 and 6.2.8 must be presented - excep! the demand thal the operating voltage must not exceed the haif of the test voltage, Chly insuiating joints that are welded or constructed in an other appropriate way can be Used. Pressed types simitar to those ia fig. 3 are not permissible in this pressure range. Appropriate material (e.g. composite coating material on the basis of phenonol-resin strengthened with paper or reinforced paper) with a minimum coating thickness of 8 mm serves as insulating material In piggable lines the inside diameter of the insulating ring must have the same size or must bbe up to at most 3 mm smaller then the inside diemeler ofthe insviating joint. in non-piggable lines the inside diameter of the insulating ting can be up fo 10% smaller than the inside diameter ofthe insulating joint,6.2.44 62.48 6.2.16 6.247 6.2.18 62.19 6.220 6.221 6.222 63 634 632 633 Ge O-ring seals with regular roundings are recommended 2s sealing material. The sealing rings must be placed on appropriate drop-shaped grooves or grooves in another shape that are found in the metallic material. Underground insulating joints must besuitably coated or wapped, Above ground insulating joints may be coated with a non-conductive material (beware of shock protection!) ‘The external coating end primer must be compatible. Factory coated insulating joints with welding ends must have an open, uncoated pipe end of atleast 150 mm, ‘The exterlor coating of insulating joints with flange connection must, corresponding to fig. 1, reach up to the flange; the sealing surface of the flange 2s well as the bearing surface of the Screw joints must be free of any coating. ‘The insulating joints must also De coated inside, in order to prevent an electrical bridge caused by a foreign efement inside the insulating joint. This interior coating can for instance be achieved by applying a PE- or EP-coating {preceding sandblasting is absolutely necessary} of a two-component high-build coating. The coating thickness must be at least 0,¢ mm and abresion-resistant, ‘The inner side must be coated as far as the sealing chamber or continuously by passing the insulating ing (Fo. 1}and es far as a eistance of 150 mm from bots welding enes. In insutating joints with flange connections the interior coating must reach on both sides up to the inner edge of the flange. Each insulating joint must be marked on a visible place with the following information ~ make - type designation + seriel number or acceptance number nominal width (ON) + nominal pressure (PN) sivel quality ofthe pipe ends ~ mark of the testing agency or of the tester. Test conditions and tests Strength analysis In the factory each insulating joint must pass a water pressure test carried out under a pressure of at least 1,5 times the nominl pressure for at least 1 minute. In this test the ends ‘must be ciosed so that the axes of the insulating joint are not under pressure. The procedure of the strength analysis can be agreed between the customer and the manufacturer. Leakage test After the water pressure test, 2 leakage test must be carried out with air under a pressure of at least 5 bar for a period of a least 10 minutes before selt-polishing. In this test leakage is not permissible. Electrical test 70.634 635 637 7 7a 72 724 722 7224 722.2 72.28 7224 Oe ach insulating joint must be tested in dry conditions with a minimum voltage of 8000 \V-(S0Hz) for 7 minute, During the test there must not ogcur a corona discharge or an insulation failure. The maximum ieakage current (at 5000 Volt, §0 Hz) depends on the capacity of the relevant insulating joint (type, size, nominal width, pressure stage, otc.) For the recommended values for the maximum leakage current sce table 1 After the water pressure test the insulztion resistance of the dry insulating joint must be at least 0,1 MQ when measuring with a direct voltage of at least 500 V. After a drying period of 5 hours at room temperature a value of at ieast 100 MO must be achieved. Exlerior coatings made in the factory must pass resist 2 non-porosity test with an alternating voltage of 25 000 V. The resulls of the non-porosity test of the exterior coating can aiso be integrated in the test Cerificate of the insulating joint. The conformity with the desired qualities and the data corresponding to 6.2.22 have to be ailested according to EN 10204 with en acceptance test certifcate 3.1.8. ‘When using steel quaiies with a yield point of > 360 Nimin?, for the open pipe ends an accopiance test certifcate 3.1. or 3.1.C according to EN 10204 is also required for the pipe ‘material (see prEN 1594) Insulating joints for operating pressures of up to 4 bar7 Insulating joints for underground installation For underground installations onty insulating joints for operating pressures of over 4 bar may be used according to sector 5 or 6. Insulating joints for exclusively above ground instalation General These insulating joints must be licensed by en accredited testing agency. Construction requirements insulating joints © DN 65 can have flanges, weld or/and other metallic connections. Insulating join's > ON 65 must nat have threaded connections The interior creep distances and air gaps must be twice as long as the shortest, exterior creep distance. ‘The exterior creep distance must be at least 3 mm, To prevent damage to the inner seal parts of the insulating joints caused by lightning or high tension interactions. eppropriete construction measures must ensure that @ possible electrical flash over can not occur inside the pipeline. An electrical flasi-over must aot affect the imperviousness of the insulating joint. In those areas where overvoltage is possible, ‘overvoltage protection measures according to 6.2.6 and 6.2.8 must be taken. 4.7.225 7226 7227 7228 723 7234 7242 Ge Insulating joints made of steel must be provided with protactive coating by the factory. ‘When installing the insulating joints be eware of the shock protection (e.g. exterior coating). Each insulating joint must be marked on a visible place with the nominal width (DN), the nominal pressure (PN) and the test mark with registration number of en accredited testing agency. Ifnecessary, insulating joints in HTB-design (higher thermic capacity 650°C for 30 min) must be installed Test concitions and tests, Strength analysis and leckage test In the factory each Insulating joint must pass a strength enelysis and a leakage test carried ‘out with air under water under a pressure of 1.5 times the nominal pressure (but at least 7 ar), The test pressure must be maintained for at least 10 minutes. In this test the ends must be closed in 4 way that the axes of the insulating joint are not under pressure. In this test leakage Is not permissible. Electrical test When applying a test alternating voltage of 2000 v at 50 Hz there must net occur break- downs of corona discharges; the test must last at least 10 seconds. The leakage current must not exceed 3 mA, When testing with 2 direct voltage of 500 V in dry conditions, the electrical resistance of the insulating joint must not be less then 100 MO. 8 Barrier fittings with integrated insulating joints for operating pressures of up to 4 bar at 82 aza 822 823 General Insulating joints that are integrated in barrier fittings must be licensed by an accredited testing agency. Construction requirements When insulating joints ave integrated in barrier filings the latter must be marked, e.g. with a red ring, on that side where the insulating joints placed Ieean also be marked with a red cap or a similar sign When the barrier fitings have @ HTB-design with integrated insulating joint, also the insulating joint must have 2 HTB-design, For the rest all the requirements of 7.2.2 shalt apply. 2Ge 23 Tests Barrier fitings with integrated insulating joints have, in addition to the test of the fiting, to be tested accarding {0 7.2.3.1 and 72.3.2. This shall apply for HTB-cesigns 9 Insulating joints for control- and measuring lines 91 General 9.1.1 This sector only appties for factory-produced, ready- width < DN 26, When insulating joints must be installed in measuring end control lines 2 DN 25, those described in sector 5, 6, 7 or 8 must be used. fi insulating joints with 2 nominal 9.1.2 When connecting with cutting or clamp ring screwing these must not be tested $2 Construction requirements 9.2.1 Insulating joints must be designed to resist 2t least the nominal pressure of pipeline. 9.2.2 The following kinds of connections are permitted: + welding end += cutting or clemp ring serewing + thread 9.2.3 These insulating joints need not be coated inside. 9.2.4 When installing these insulating joints be aware of the shock protection (e.g. exterior coating). 9.25 To prevent damage to the inner seal parts caused by to ightning or high tension interactions, construction measures of the insulating joints must ensure the overvoltage protection. 9.2.6 The interior creep distances and sir gaps must be twice as tong es the shortest, exterior creep distance. ‘The thickness of the insulating material must be at least 8 mm. 8.2.7 Each insulating joint must be matked on a visible place with the folowing information: + manufecturer andior registered trade-mark = norninat wicth (DN) and nominal pressure (PN) - type designation. 92.8 Ifa test mark of an accredited testing agency is available the marking mentioned above is tunnecessary when the registration number is engraved and the registration certificate is handed over. 22.9 All qualities must be proved in writing, A test mark of an accredited testing agency is equivalent 9.3 Test conditions and tests a93.4 93.2 93.3 10 10.4 10.14 1042 1043 10.1.4 10.1.5 10.1.6 10.1.7 10.18 102 10.2.4 10.2.2 G@ In the factory each insulating joint must pass a strength enalysis and leakage test carried out with air under water uncer a pressure of 1,5 times the nominal pressure, The test pressure must be maintained for at least 10 minutes. Wien epalying a test alternating voltage of 2000 V et 60 Hz there must not occur break- owns or corona discharges. The test must last at least 1 minute, The leekage current must not exceed 3 mA, When testing with a irect voltage of 500 V in dry conditions the electrical resistance of the insulating joint may not be less than 100 Ma. Ready-to-fit insulating flange joints General The insulating flange joint is an electrically insulating, non-positive flange Jeint, that is pre- fited in the factory. Tho pressure class of the insulating flange only depends on the pressure cless of both flanges For every type of construction or for 2 modification of the original construction plan, a prototype testing by an authorised testing agency (accredited testing laboratory) must be proved The components of insulating flange joints must be tested, The test results must be proved in writing end presented to the customer. Insulating flange joints destined for installation into gas pipelines made of steei must, according to their pressure class, correspond to EN 16208 and must be designed to resist the nominal pressure of the line, When the test pressure of the line does not exceed the test pressure of the insulating flange joint, the latter can also be installed into the line before the pressure ofthis line is tested. When installing the Insulating flange joint be aware of the shock protection (e.9. exterior coating) ‘After the pneumatic and leakage test of the pipeline the electrical insulating capacity of the insulating flange [oint must be tested according to fig. 17 and 12. Construction requirements The ready-torfit insulating flange joint generally consists of + two preswelded flanges insulating parts (disks and cases) bolts, nuls, shims sealings welded pipe parts or flanges The non-productive insulating flange joint that is presfited in the factory must be installed into the pipeline without disassembly. +41023 102.4 102.5 10.2.6 1027 1028 10.29 102.10 102.11 102.12 10.213 10.3 10.3.1 Sec For the insuiating parts of the insulating flange joint a composite layer material with high compressive strengtr and good dielectrical qualities must be used. The material for he prossure loaded parts must correspond to the EN 10208. The insulating flange joints must be seeled by flat seaiings or O-ring-seaiings, ‘The customer has to specify the desired stee! quality of the welcing ends. The welding ends nave to be designed corresponding to EN 10208-1, table 10, ‘The insulating flange joint must be designed for a minimum temperature range of the medium from - 10°C up to + 80°C. Differing teriperetures must be specified by the customer. To prevent damage to the inner seal pars of the insulating flange joints owing to lightning or high tension interactions, appropriate construction measures must ensure that @ possible electrical flash over can not occur inside the pipeline. An electrical flash over must not affect the imperviousness of the insulating flange joint. in order to protect an insuieting flange Joint against flash overs owing ‘0 lightning and high tension interactions an overvoltage protection device with a maximum operating impulse voltage according 10 half of the test voltage (withstand alternating voltage) of the lnsulating flange joint and with a leakage impulse current of 50 kA (waveform 10/350 iss corresponding t01EC 1024-1 and IEC 1312-1) must be provided. The overvoltage protection device should be fixed directly on the insulating Joint (maximum loop length 300 mm). in special cases the overvoltage protection device can be fixed above ‘ground at an accessible measuring point if the lengthened line feed is designed with the lowest impedance possible corresponding to the determined tength of the loop. To be ‘efficient the overveltage protection device must be connected with the insulating joint with a maximum connection inductance of 0,3 nH. This can be obtained by using a maximum loop length of 300 mm or other tine feeds with low impedance, e.g. co-axial cables, drilled lines, ete. whose total inductance does not exceed 0,3 aH and Is resistant to high lightning current (at least 16 mm? Cu according to IEC 1024-1) If the insulating flange joint is placed in an explosive gas atmosphere @ surge arrester with the respective licensing corresponding to EN 50014 must be used. tn this case iis important to consider that the connection on the insulating flange joint also has to be explosions-proof. Each insulating flange joint must be marked on a visible place with the following information: + make type designation sotial number of acceptance number nominal width (DN) and nominal pressure (PN) imerk of the testing agency or of the tester. Wien using pipe parts that are welded on both sides also the steet quaity of these pipe ends must be marked Test conditions and tests Strength analysis In the factory each insulating flange joint must pass a water pressure test carried out under a pressure of 1.5 times the nominal pressure for least § minutes. In this test the ends must be closed in a way that the axes of the insulating flange joint are nat under pressure 610.3.2 10.3.3 103.4 10.35 103.6 037 1 WA 44 14.2 143 GG The procedure of the strength analysis can be agreed between the customer and the manufacturer. Leakage test Alter the water pressure lest, 2 leakage test must be carried out with ait under a pressure of 5 bar for @ period of at least 10 minutes before self-polishing, In this test leakage is not permissible. Electrical test Eoch insuleting flange joint must be tested in dry coneitions with 2 minimum voltage of 5000 \Y~(S0Hz) for 1 minute, During the test there must not cocur a corona discharge or an insulation faut. The maximum teakage current (at 6000 Volt, 50 Hz) depends on the capacity of the relevant Insulating flange joint (type, size, nominal width, pressure stage, etc.) For the recommended values for the maximum leakage current see table 1 After the water pressure test the insulation resistance of the dry insulating flange joint must be at least 0,1 MO when measuring with a direct voltage of at least 500 V. Afler a drying period of § hours at room temperature a value of at least 100 MO must be achieved. Extemai coatings made in the factory have to resist @ non-porosity test with an alterneting voltage of 25.000 V, ‘The attestation of the non-porosity test of the exterior coating can also be integrated in the test certificate of the insulating flance joint. The conformity with the desired quaities and the date corresponding to 10.2.13 must be altested according to EN 10204 with en acceptance test certificate 3.1.8 3.1.4 or 3.1.C for pressures of over 16 ber. When using for the open pipe ends sioe! qualities with a yield point of > 360 Nimm#, an acceptance test certficate 3.1.8 or 3.1.6 according to EN 10206 is required for the pipe material. Insulating flange pairs General ‘The insulating flange pair is an electrically insulating, non-positive flange joint thet is pre-fitted in the factory and must be taken apart in order to weld it into the gas pipeline. ‘The pressure class of the insulating flange joints only depends on the pressure class of the both flanges. For every type of construction or for a modification of the original construction plan, a Prototype testing by en authorised testing agency (accredited testing laboratory) must be Proves.i144 148 W416 Maz 1418 12 24 1122 11.2.3 11.24 11.25 11.28 27 1.28 1128 Gc The components of an insulating flange pairs must be tested. The test results must be proved in writing and presented to the customer. Insulating flange pairs destined for installation into gas pipelines made of steel must, according to their pressure class, correspond to EN 10208 and must be designed to resist the nominal pressure of the fine. When the test pressure of the line does not exceed the lest pressure of the insulating flange pair, the latter can also be installed into the line before the pressure ofthis ine is tested ‘When instaliing the insulating flange pairs be eware of the shock protection (e.g, exterior coating) Afier the pneumatic and leakage test of the pipeline the electrical insulating capacity of the insulating ftange pair must be tested according to fig, 11 and 12. Construction requirements The ready-torfit insulating flange pair generally consists of: ~ two pre-welded flanges - insuiating parts (disks and cases) + bolts, nuts,shims sealings The insulating flange pair that is presfitted in the factory must be disassembled before welding it into the pipstine, in order to avoid the destruction of the insulating and seaing material. For the insufating parts of the insulating flange pair @ composite layer material with high compressive strength and good dielectrical qualities must be used. ‘The material for the pressureloaded parts must comply with the EN 10208. The insulating flange pairs must be sealed by fat sealings or O-ring seatings. ‘The insulating flange pair must be designed for @ minimum temperature range of the medium from - 10°C up to + 50°C. Differing temperatures must be specified by the customer. To prevent damage to the inner seal parts of the insuleting flange pir owing to lightning o high tension interactions, spprepriete construction measures must ensure that a possible electrical flash over can not occur inside the pipeline. An electrical flash over must not affect the Imperviousness of he insulating fange pai. To protect ar insulating flange pair against flash overs owing to lightning and high tension inlerections an overvoitage protection device with a maximum operation impulse voltage according to the haif of the test voltage (withstand alternating voltage) of the insulating fange pir and with a leakage impulse current of 50 kA (waveform 10/360 js corresponding to 1EC 4024-1 and IEC 1312-1) must be provided. ‘The overvoltage protection device should be fixed directly on the insulating joint (maximum {oop length 300 mm). In special cases the overvollage protection device can be fixed above ground at an accessible measuring point if the lengthened iine feed is designed with the lowest impedance possitle corresponding to the determined length of the loop. To be efficient the evervoltage protection device must be connected with the insulating joint with a ‘maximum connection inductance of 0.3 41H. This can be obtained by using @ maximum loop length of 300 mm or other line feeds with low impedance, e.g. co-axial cables, driled lines, a112.40 112.11 3 1134 14.82 133 ec otc, whose total inductance does not exceed 0,9 HH and is resistant to high lightning current (atleast 16 mm? Cu according to IEC 1024-1) Ifthe insvlating flange pair is placed in explosive gas atmosphere a surge arrester with the respective licensing corresponding to EN 50014 must be used. In this case it is important to consider that the connection on the insulating flange pair alsc has to be explosions-proof. Each insulating flange pair must be marked on a visible place with the following information: ~ make - type designation serial number or oceptance number nominai width (ON) and nominal pressure (PN) + mark of the testing agency or of the tester. Test conditions and tests Strength enalysis and leakage test The strength and the imperviousness of insulating flange pairs does not need to be tested in the factory, Electrical test ‘When appiying @ test altemating voltage of $000 V at 50 Hz there must not occur break- owns or corona discharges. The test must last at least 1 minute, The leakage current (at 8000 V, SO Hz) depends on the capacity of the relevant insulating fange pair (type, size, nominal wiath, pressure stage, etc). For the recommended values for the maximum leakage current see table 1 ‘When testing with a direct voltage of 500 V in dry conditions the electrical resistance of the insulating flange pair must not be less than 100 MQ The conformity with the desired qualities anc the data corresponding to 11.2.must be attested zocotding to EN 10204 with en acceptance test certificate 3.1.8 3.1.A or 3.1.C for pressures, of over 16 bar. a44 12 13 14 15 24 22 23 24 25 28 27 28 Gc Annox 1 Arrangement and Installation examples of insulating jints ‘The instalation of insulating oh into vertical ne sections is prefered, so that an electrical bridge by conductive foreign elements inside the insulating joint will not occur. Instalation of insulating joints into house-connection lines and buried supply pipes - fig. 17 to 22. For reason of shock protection insulating joints have to be installed info these lines made of steel in the gas flow direction immediately after the inlet and before the outlet of the building, ‘This also applies to ines made of plactic when the transition to lines made of steel occurs in the underground, Installation of insulating joints into buried pipelines according to chapter § - without istration. Installation of insulating jcints into gas pressure regulators and into valve stations according to chapter 5 -fig. 14 to 16 and 230 31. Installation of insulating jeints into measurement. and contro’ lines according to chapter 5 - fig. 8 Installation of insulating joints into pipelines on bri¢ges according to chapter 5 - fig. 92. Location and installation of measuring cables when installing insulating joints, Each instelled insulating joint must have a measuring point on both sides, lf direct measuring is impossible measuring cables must be installed. ‘The measuring cables must be terminated at a measuring point, These measuring points can be installed in street, wall- or detached boxes. ‘The measuring cables must not end in areas where an explosive gas atmosphere exists (unless special precautions are taken.) lr measuring cables must be buried, only double-insulated cables are permissible. Measuring cables must not have @ metal sheath and cores must not be marked with green and yellow . Moreover they must have @ minimum diameter of 10 mm® CU or 2 x 4 mm® Cu. For cables for the exterior connection of surge arresters see chapter 5.2.7. ‘The transition resistance between the used measuring cables and the pipeline must be very small (some 412). Therefore the connections of the measuring cables should be manufactured by welding, soldering or special thermit welding procedures. Adhesive procedures or connections by clamps ere to be avcided ln no case may the measuring cables may be installed on the insulating joint itself er directly ‘on the round weld (cistance from the weld at feast 100 mm). 78.29 2.40 Ge Electrical connections on the surface of the pipes must be manufactured by a welding procedure that does not elter the qualities of the material. When appiying thermit welding or stud welding procedures for the production of cable connections for the cathodic protection, the qualification of the welder for welding on a building site must be tested before welding, In this test it must be proved that the metallurgic structure of the pipe material is not affected through the welding of the cable, ‘The preparation of the pige surface, the connection method as well as the welding can only bbe made by trained personnel. The adhesive strength of the welds and the integrity of the cable connections must be tested ‘The connection points of the measuring cables must be suitably ccated. 2,Fig. Fig. Fig. Fig. Fig. Fig Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig. Fig, Fig. Fig. Fig. Fig, Fig. Fig. Fig. " 12 14 18 16 v7 18 19 20 24 22 23 Annex 2 Nustr ions (informative) ‘The following ilustrations are basic exemples end are not complete. General structure of a ready-to-ft insulating joint with integrated ring spark bridge Various kinds of ready-to-it insulating joints Insulating joints; suitable for the aboveground installation up to DN 50 and 4 bar Insulating joints; suitable for the aboveground installation up to 4 ber ‘Schematic description of overvaltage protection devices on insulating joints Barer fittings with integrated insulating joint for operating pressures of up to 4 bar Examples for the diferent kinds of berrierfitings with integrated insulating joint for operating pressures of up to 4 ber Example for an insulting joint for the installation into control and measurement fines Ready-to-it Insulating flange pair Insulating flange pair with overvoltage protection device Testing an insulating joint by measurement of the vollage drop Testing en insulating joint by measurement of the electrical field Surge arrester in the measuring box Simplified cireult diggram - valve stetion or similar installations; no insulating joint in the main fine Simplified circuit diagram - valve station or simiar installations; insuiating joint in the main fine Leadsin of @ pipe into a buitcing Insulating joints in house-connection ling; house-connection line made cf stee! No insulating joint in house-connection line; house-connection line made of PE Insulating joint in house-connection fine; house-connection tine made of PE = transition to stee! before wall entrance No insulating joint in house-connection line entrance unit house-connection line made of PE - wall Insulating joints in buried supply pipe Insulating joint in buried supply pipe - parlly leid in pipe channe! Insulating jeints in detached control box aadior meter case made of metal or concrete (foundation made of reinfarced concrete} aFig. 25 Fig. 26 Fig. 27 Fig. 28 Fig. 29 Fig. 20 Fig. 31 Fig. 32 Go Gr Insulating joints in detached control box andlor meter case made of metal or concrete (foundation made of reinforced concrete) - house-connection line made of PE - transition to lee! bofore init into the box (case) Insulating joints in detached contra! box ancfor meter case made of meta! or concrete (foundations made of reinforced concrete) - house-conrection line made of PE - transition to ste! immediately at the inlet into the box (case) Insulating joints in detached control box andlor meter case made of plastic (foundations made of plastic) Insulating joint in detached contro! box anclor meter case made of plastic (foundations made of plastic}; house-connection line made of PE - transition to steel before inlet info the box (case) No insulating joint in detached control box endfor meter case made of plastic (foundations made of plastic), house-connection line made of PE - ttensiion fo stee! immediately at the inlet into the box (c2se) Insu‘ating joint in control box endfor meter case at oF in the exterior house wall, house- Connection line made of steel or PE with transition to steel before the init into the box (case) No insuteting joint in control box andlor meter case at or in the exterior house wall; house- connection line made of steel or PE - transition to steel immediately al the inlet into the box (case) Insutating joint in contro| box and/or meter case at or in the exterior house wall; house- connection line made of stee! or PE with transition to steel before the inlet into the box (case}- lead-in of the steo! ling into a building without celle. Steel lines on bridges: interruption of he cathodic protection in bridges through installation of insulating joints (basic scheme) 22,LEGEND Eo Gr PIPELINE MAIN INNER PIPELINE EXTENSION EXTENSION FUSE SLEEVE STEEL/PE JOINT WALL ENTRANCE UNIT INSULATING FLAGE INSULATING JOINT LOCK FITTING LOCK FITTING WITH INTEGRATED, INSULATING JOINT PRESSURE CONTROL DEVICE GAS METER% wilinal cod Dimension C= according to 5.2.12 5.2.13 6.2.12 6.2.13 exkanal coating ST | intenface, (ensolak: oye rng, ) ang. spor bac | Keb aA baclae Ts Coop dae) antue cRaamber. Installation options ~ both sides welded extensions - both sides flange extensions ~ one side flange - one side welded extension free welding end a= 150mm free pipe end at - electric welding b= 100mm - oxyacetylene welding b> 250 mm a6puiq weds Bunejnsuy yy-oy-Apeai & Jo oumondys jeiauag 4, “Bly = 5 z 5 a a 5 & = 3 éGG Fig. 2. Various kinds of ready-to-fit insutating joints Tansnlatin oF pW onlenteo av ovlatny: poe oa les 25GoGe Fig. 3 Insulating joints; suitable for the aboveground installation up to DN 50 and 4 barGG its; Suitable for tl \d installation up tGe Fig. 5 Schematic description of overvoltage protection devices on insulating he 2xtinsd oe ‘ink ot ‘pousib) fw aGG Fig.6 Barrier fittings with integrated insulating joint for operating pressures of up to 4 barcrf LiGe Fig. 8 Example for an insulating joint for the installation into control and measurement lines= Fig. 9 Ready-to-fit Insulating flange pair cnselating sacs tstabng aise = IT olor ns - eH- ——d 4 aut? Lack Bast Exxompl 11 Texel flange IT padced bow both acdea RB Ones 40 on bok Acces Cxomple 2: Beveled por Acth Gaish udEo Ge Fig. 10 Insulating flange pair with overvoltage protection device qpefinition [fk aad Rie Stiakim gcde- tk IRE RE doup eBey0A up jo quswounseow Aq juiol Bugeinsul ue BuyseL | “Bld Ut potential drop at pipe UT IK potentiat drop at pipe 11K current in insulation 11__ pipe current U2IK difference potential RIK resistance of insulation KG rectifier IKG rectifier voliage URE current in the earth R_ pipeline resistance Length pipe length RE earth resistanceee Fig. 12 Testing an insulating joint by measurement of the electrical fieldGe Fig. 13 Surge arrester in the measuring box Mensuring bEXC meter) “Gage allverer C/O oO Clasups fe coat. min, ixte pube nes On: Y 75 Ohm petype E-YY0 42,5 electTcat My terfaceGc Fig. 14 Simplified circuit diagram - valve station or similar i installations; no insulating joint in the main line i hs peal IHR THN ab-2 brands pipe. aGe Fig. 15 Simplified circuit diagram - valve station or similar installations; in the main line insulating joi@e Fig. 16 Lead-in of a pipe into a building || coahig of engkshig Li pot bs dike coated (Gch frofechon)Gee Fig. 17 Insulating joints in house-connection line; house-connection line made of steel RRM YY HNMNAN eee steel \ - +Fig. 18 No insulating joint in house-connection line; house-connection line made of PEEG Fig. 19 Insulating joint in h ection lin louse-connecti house-connection line made of PE - transition to steel befor ion lino; re wall entranceGe Fig. 20 No insulating joint in house-connection line; house-connection line made of PE - wall entrance unit ae MUM OM OO808uiWWWMN La COU bedftanite. Utiuf a Stel i= MULL i. Y aiGe Fig. 21 Insulating joints in buried supply pipeGe Fig. 22 Insulating joint in buried supply pipe - partly laid in pipe channel€oG $ 3 — 2e ge 52 a Eg go 35 oe ge 8 3 3 2 8 8 3 rete (foundation made of rei metal or con: Fig. 23 Insulating joints in detach crGe ‘tached cont made d el before trol box and/or meter case reinforced con to ster ints in deta ee or concrete (foundation made of i lade of PE - transition 3 £58 S25. ges £53 Boe gHe Bo§ £8 a 2 it (case)@C Fig. 25 Insulating joints in detached control box and/or meter case made of metal or conerete (foundations made of reinforced concrete) - house- connection line made of PE - transition to steel immediately at the inlet into the box (case) | 48.trol box ani tached cont joints tn latin: s in deta plastic (foundations made of plastic) Insuk Fig, 26 we és tad on “beltceal bay & he Mule pipetne f eae ( gee pic 23) ef Be rmachen sats Ba Auried haceFig. 28 No insulating joint in detached control box and/or meter case made of plastic (foundations made of plastic); house-connection line made of PE - transition to steel immediately at the inlet into the box (case) a o He mssclde ak cs earlbed an Jeiead cntifiace peusk de buill uate’ the ashofe peopel (ae £3 1s)! prisGe ig. 29 Insulating joint in control box and/or meter case at exterior orin the e ‘ion line made of steel or PE with transition se) house wi se-connectior to steel before the inlet into the box (ca: fall; houssoe at or in the exterior ntrol box and/or meter case Fig. 30 No insulating joint in co hol - transition to line made of steel or PE nection steel immediately at the inlet into the box (case) use wall; house-cont | aa@ Ge Fig. 31 Insulating joint in control box and/or meter case at or in the exterior house wall; house-connection line made of steel or PE with transition to steel before the inlet into the box (case)- lead-in of the steel line into a building without cellar.Fig. 32 Steel lines on bridges; interruption of the cathodic protection in bridges through installation of insulating joints (basic scheme) 3 to 3S st Ye Ba § » Ss N = sb 5 € & a AS} => 3 § = Uo = § 5 3 a 33 BS x 3°