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SPECIFICATION FOR INSULATING JOINT

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IGAT 6 D PL ME SPC 0005 02 13 1

SPECIFICATION FOR INSULATING JOINT

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SPECIFICATION FOR INSULATING JOINT



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Table of Contents

1. Introduction
2. Scope
3. Definitions
4. Codes and standards
5. Material
6. Design requirements
7. Welding and Fabrication

SPECIFICATION FOR INSULATING JOINT



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8. Inspection and testing


9. External & internal protection
10. Reports and certificates
11. Shipment

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1- Introduction
Iranian Gas Engineering & Development Company (I.G.E.D.C) has intended to perform gas
transmission pipeline and gas compressor stations for transferring of 110 MMSCMD of natural
gas to be fed from South Pars phases 22 ~ 24 from Assalouyeh to Bazargan.
Design of a new 56" gas transmission pipeline from Assalouyeh to Bazargan has been
described under this EPC Contract.
2- Scope
This specification covers manufacturing, inspection, testing and preparation of shipment for
insulating joint installed and forming part of the corrosion protection of sweet Natural Gas
Transmission pipelines and associated distribution systems based on specification No.

0 IPS-M-TP-750(part 8) & IGS-M-PL-006(1).


1
Insulating joint shall be suitable for installation in a pipeline with the service conditions as well
as the pipeline material.
Chemical composition of associated pipeline shall be as stated in enquiry matching line pipe.
Pipeline nominal diameter along with its wall thickness shall be specified on the purchase
order by the purchaser.

3- DEFINITIONS
Client: Iranian Gas Engineering & Development Company (IGEDC).
MC: Ghods Niroo Consulting Engineers.
CONSULTANT: Haraz Rah Consulting Engineers.
CONTRACTOR: Gharargah Khatam-AL-Anbia.Niroo Goostar Institute.

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4- Codes and standards


ASME B 16.5 Pipe flanges & flanged fittings NPS 1/2" Through NPS 24"
BS 5493 Code of practice for protective coating or iron and steel structures against
corrosion
MSS-SP-75 Specification for high test wrought butt welding fittings
MSS-SP-44 Steel Pipeline Flanges
ASME SECTION VIII (div1) Rules of construction of pressure vessels
ASME SECTION IX Welding and brazing qualifications
IPS-M-TP-750(part 8) Material & Equipment Standard for Cathodic Protection
ISO 10474 Steel and Steel product inspection document
ISO8501 (part1, 2) Preparation of Steel before Application of paint & Related Products
IGS-M-PL-006(1) Specification for insulating joint
0 4-1 Insulating joint furnished shall conform to the ASME/ANSI B16.5, and shall be
1
manufactured in accordance with the standards specified herein and as further supplemented in
this Specification.
4-2 The latest editions and revisions are intended.

5- Material
5-1 The metallic parts of the insulating joint shall be of forged steel conforming to the
requirements of MSS-SP-44.

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5-2 Forged fully killed, normalized or hardened and tempered materials will have to be used
according to the schedule here below:
API 5L X42 ASTM A694 GR. F42 OR F52
API5L X52 ASTM A694 GR.F52
API 5L X60 ASTM A694 GR. F60
API 5L X60 ASTM A694 GR. F65
API 5L X70 ASTM A694 GR. F70

5-3 The carbon equivalent calculated with the following formula shall not exceed 0.42%:

C.E. = C + Mn/6
C.E. = Carbon Equivalent
C = Carbon
Mn = Manganese

6- Design requirements
6-1 The insulating joint shall be of boltless monoblock type fabricated with pups on either side .
If closure weld is performed on the final assembly its features shall be so designed to eliminate
possible damages to the seals and / or the insulating rings, due to generated heat. Insulating
gaskets shall be made of suitable material which fully satisfies the requirements of section 5.8 of
IPS-M-TP-750(8) and shall be made of fluorocarbon copolymers like Teflon or similar materials.
6-2 Insulating joint shall be designed following methodology described in ASME SECVIII
DIV1, APP.2.
Each manufactured insulating joint shall be assembled and tested according to the requirements of
this specification. Manufacturers shall describe relevant manufacturing method for each specific
model offered and clearly present shape, number, and material of their offered seal and insulating

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materials.
6-3 Construction should not incorporate any flange bolting, gasket and shall be rigid and rugged
design suitable for field installation without a maintenance pit when installed either on a buried
or surface laid pipeline. ANSI class rating 150 to 600 and temp. Range from -29 to 85 degrees
C.
6-4 End connections will not be flanged but shall be beveled for welding in accordance with
MSS-SP-75, unless otherwise specified to allow welding to the pipeline with only two
circumferential butt welds. Transition pieces shall be incorporated if necessary as stated in the
enquiry.
6-5 The insulating material used for electrical isolation shall be capable of sustaining high
compressive stresses, and shall be of good long-term stability and of excellent dielectric strength.
6-6 Tension and compression shall axially be transmitted satisfactorily and without appreciable
elongation or contraction.
The coupling shall indicate no permanent deformation when under maximum pressure and
temperature.
6-7 Primary and secondary sealing system against possible leakage is required.

6-8 The insulating materials and filler materials shall be suitable for the long-term exposure to
the transported fluid at the design pressure and temperature conditions. Primary and secondary
sealing gaskets shall be so designed that the joint assembly complies with the mechanical and
electrical requirements specified in this Standard specification. The seal gaskets must oppose the
fluids internal pressure at the same height from the two sides of the rigid insulating ring. Sealing
systems which foresee o-rings cannot be accepted.
6-9 The minimum overall lengths for the joints (as measured between ends) of given size and

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pressure class shall be as follows:

ANSI CLASS RATING PIPE SIZE


DN
1500 900 600 400 300 150
mm 1000 mm 1000 mm 1000 mm 1000 mm 700 mm 700 Up to 350
mm 1500 mm 1500 mm 1500 mm 1200 mm 1000 mm 1000 to 600 400
mm 2000 mm 2000 mm 2000 mm 1800 mm 1500 mm 1500 to 900 650
mm 2800 mm 2800 mm 2500 mm 2200 mm 2200 mm 2000 to 1200 950
mm 3200 mm 3200 mm 3000 mm 3000 mm 2800 mm 2500 to 1250
1500

7- Welding and Fabrication


7-1 Welding and qualifications of the weld shall conform to ASME code for pressure piping
Section VIII and IX as applicable.
7-2 The number of welding must be restricted as possible. All joints shall be butt welded and
have full penetration except for the final closure weld. The final closure weld shall be in
accordance with ASME SECVIII, DIV.1 ULW17.6 fig A.
7-3 All butt welds shall be heat treated after all welding has been accomplished in accordance
with requirement of ASME, SECVIII.
7-4 Tack welding of protectors to the joints is not permitted.

7-5 The height of internal weld beads shall be less than 2 mm.

7-6 Under-cutting on weld seam shall not be permitted.

7-7 The assembly of insulating joint(s) shall be done in a controlled, clean environment.

7-8 The insulating joint(s) shall be assembled in such a way that its various components are
firmly locked in position and the complete joint is capable of withstanding stresses due to
designed operating conditions and field hydrostatic testing.

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7-9 The surface of the annular space between the pup and the retainer shall be abrasive shot-
blasted to SA 2 grade in accordance with ISO 8501-1. Assembly of the insulating joint shall
commence within 2 hours after completion of abrasive shot blasting.
7-10 The annular space between the retainer and the pup shall be filled with an epoxy resin filler
material; to be approved by the Purchasers representative. Any depressions in the insulating
joint shall be filled with adhesive sealant elastomer to prevent the deposition of sediment at this
point.

8- Inspection and testing


8-1 Each joint shall be individually inspected and batch testing not permitted.

8-2 All welds on the joint are to be butt welds and shall be radio graphed by X-ray. For closure
welds ultra sonic inspection is acceptable.
8-3 The complete insulating joint, together with any transition pieces, shall satisfactorily perform
an electric insulation test which shall indicate that side to side measurement of resistance are not
less than four (4) MEGA OHMS when impressed with a potential of not less than one thousand
(1000) volts D.C.
The above described insulating joint shall also satisfactorily perform a dielectric test at three
thousand (3000) volts A.C. fifty (50) Hz. during one minute. Each insulating joint shall be
electrically tested before and after hydrostatic test.
8-4 The complete assembled insulating joint, together with any necessary transition pieces shall
satisfactorily sustain a hydrostatic test pressure of not less than 1.5 times the class rating,
specified as in the code. Unless otherwise stated in the purchase order the specified test pressure
shall be maintained for three (3) hours without loss of pressure.

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8-5 Test of material, selection of rolls which insulating joint made of it shall meet all
requirements that specified in ASTM test method D 1000.
8-6 An inspection certificate shall be provided by the manufacturer in accordance with the
following:
a) ISO 10474 Type 5.1.B for chemical analysis, mechanical properties, notch toughness properties,
hardness properties, heat treatment and non-destructive examination.
b) ISO 10474 Type 5.1.C for other tests, e.g. dimensional checks, pressure test (when specified),
functional checks
8-7 Purchasers inspector(s) shall have free access to the manufacturers works to follow up the
progress of the materials covered by this Part of Standard specification and to check the quality
of materials. The manufacturer/supplier shall place free of charge at the disposal of the
Purchasers inspector(s) all means necessary for carrying out their inspection: results of tests,
checking of conformity of materials with this Standard requirements, checking of marking and
packing and temporary acceptance of materials.
8-8 The Purchaser reserves the right to perform any inspections set forth in this Part of Standard
specification where such inspections are deemed necessary to assure that supplies and services
conform to the prescribed requirements.
8-9 All tests which mentioned in IPS-M-TP-750 (PART8) shall be carried out.

9- External & internal protection


9-1 The insulating joint shall be externally coated with chlorinated rubber paint system according to
BS-5493 to a dry film thickness of 500micrones.
9-2 The insulating joint shall be internally coated with amine cured epoxy paint to a dry film

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thickness of 500 microns.


9-3 After all tests and inspections required have been carried out, insulating joints shall be
thoroughly cleaned in order to remove rust or impurities. Surface preparation shall be carried out by
shot blasting or sand blasting to SA 2 grade in accordance with ISO 8501-1. After visual inspection,
all insulating joints shall be externally and internally coated with amine cured epoxy paint to a dry film
thickness of 500 microns applied in two coats. The application shall be in strict accordance with the
coating suppliers specification. Beveled ends for 50 mm approx. shall be painted with rust preventive
paint.
10- Reports and certificates
The supplier shall furnish the Purchaser with five complete copies of the followings and as specified in
the Purchase order.
a- Certificate of shop inspection.
b- Weld procedure.
c- Certified reports giving chemical analysis and physical properties of steel
d- Stress relieves and heat treatment certificates
e- Non destructive test certificates
f- Hydrostatic test certifications
g- Electrical insulation test certificates
h- Catalogues
i- Manufacturing certificates.
11- Shipment
11-1 Both ends of each insulating joint shall be covered by means of wood of suitable material to
protect the internal parts and also the beveled ends from any possible damage.
11-2 The package shall be appropriate for storage without cover. Indent number and the specific

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item number shall be clearly identified on each package.


11-3 As specified in IPS-M-TP-750(part 8) , insulating joint shall packed to protect any damage
which occur during transit and extended tropical open air storage up to 24 month.