ドッペルギャンガー クレイジータープ TT5-48 【ビーズ ヘキサ テント タープ
Contents
1. 33 he Deforihon A i Shkon side U1 potential drop at pipe 11 pipe current KG rectifier R pipeline resistance R a lik and R IK SRL scde IKG I RE RE KG jrofechon sde U1IK potential drop at pipe IIK current in insulation U2 IK difference potential R IK resistance of insulation IKG rectifier voltage RE current in the earth Length pipe length RE earth resistance doap Beyoa ay Jo Juawainseow Aq juto Bugejnsul ue Bunso LL Big Go Gr Fig 12 Testing an insulating joint by measurement of the electrical field 35 G Fig 13 Surge arrester in the measuring box Measuring LEX L ME surge diverter T Caps Cat min 1x16 3 d min h 16 EYY0 42 4 EYY0 42 5 Fc 4 2 CU 2Y 75 Ohm T ba D BS Lanni rus 1 elechicatl In TEL POLE EE Fig 14 Simplified circuit diagram valve station or similar i insulating joint in the main line SSN SS KIKEL GULLY ns S A rRNA RRRA RS tallations no NN SISISISSISS brauch P jpe 37 Go Gr Fig 15 Simplified circuit diagram vaive station or similar installations insulating joint in the main line T D bs 4 ahon bjarta Pip 38 Bo Gr Fig 16 Lead in of a pipe into a building CG Fig 17 Insulating joints in house connection line house connection line made2. C INSULATING JOINTS FOR GAS PIEPELINES Quality testing and arrangement of insulating joints in gas pipelines E Cr CONTENTS Pr face 1 Scope 2 Functions and applications of insulating joints 3 Terminology 4 General Insulating joints for operating pressures of more than 16 bar Insulating joints for operating pressures of over 4 bar up to 16 bar Insulating joints for operating pressures of up to 4 bar 8 Barrier fittings with integrated insulating joints for operating pressures of up to 4 bar 9 Insulating joints for control and measuring lines 10 Ready to fit insulating flange joints 11 Insulating flange pairs aa kw wow 12 13 14 16 1 2 1 2 2 2 3 2 4 Preface This technical recommendation for the 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 joints in pipelines and plant 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 guarantee and dher commercial aspects Functions and applications of insulating joints An insulating joint is a non conductive pipe connection that interrupts the
3. apuq yseds buy paeabayui yam jurof Bunejnsul 1y 0 Apeal e Jo aunjonizs jelsus9 614 45 9 E amp E Fig 2 Various kinds of ready to fit insulating joints Tmidlaling pet att lt xkension pr oven EME prolechen EE Fig 3 Insulating joints suitable for the aboveground installation up to DN 50 and 4 bar 26 GG G Fig 4 Insulating joints suitable for the aboveground installation up to 4 bar Hanga BNG NGA Go Gr Fig 5 Schematic description of overvoltage protection devices on insulating joints QZ INN EL a Sun he extension ig rs AO BIG Yok bsa Enon KP 2 mb on whe LS Gr Fig 6 Barrier fittings with integrated insulating joint for operating pressures of up to 4 bar Go Ge HR e amipies sfo ne an ent kinds of bari operating pi er fittings with integrated sulating joint for ssures of U Gas S S n Lal C6 Fig 8 Example for an insulating joint for the installation into control and measurement lines D C 8 10 12 iG Z mam ka Rr AR Fig 9 Ready to fit Insulating flange pair insulates Have Se i E S E ai hack E Eat ee one Phot aden EE Saut Cable PA DB 01 J i ae ath Gui sF oud O nng Anla on bol Acces Go Gr Fig 10 Insulating flange pair with overvoltage protection device
4. 8 must be presented except the demand that the operating voltage must not exceed the half of the test voltage Only insulating joints 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 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 be up to at most 3 mm smailer 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 6 2 14 6 2 15 6 2 16 6 2 17 6 2 18 6 2 19 6 2 20 6 2 21 6 2 22 6 3 6 3 2 6 3 3 Eo Ge O ring seals with regular roundings are recommended as 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 besuitabiy 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 compatible Factory coated insulating joints with welding ends must have an open uncoated pipe end of atlea
5. PN steel quality of the 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 nominal pressure for at least 5 minutes In this test the ends are to be closed 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 a leakage test must be carried out with air under a pressure of 5 bar for a period of at least 10 minutes before self polishing In this test leakage is not permissible Electrical test GY r Each insulating joint must be tested in dry conditions with a minimum voltage of 5000 V 50HZz for 1 minute During this test there must not occur a corona discharge or an insulation failure The maximum leakage current at 5000 Voit 50 Hz depends on the capacity of the relevant insulating joint type size nominal width pressure stage etc For the recommended values for the maximum leakage current see table 1 Table 1 Recommended values for the maximum leakage current composed of ohmic and capacitive current lt PN 16 lt PN 70 lt PN 100 3mA lt ON 800 lt DN 400 lt DN 200 10 MA gt DN 800 gt DN 400 gt DN 200 lt ON 1200 s DN 800 lt DN 600 After the water pr
6. exterior house wall house connection line made of steel or PE with transition to stee 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 33 j Y 29 N 21 2 NEw Ss Ks G x S NG E c electrically condu ing Gy ucton brid Con 55
7. is an overvoitage protection device integrated in the insulating joint 4 General 44 The factory must produce the insulating joints so that they are ready to fit and that they conform to the technical requirements for construction quality and pneumatic test for the proposed installation 42 The material used seals 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 lose their effectiveness if imperviousness is tested or moisture penetrates 44 In order to avoid the danger of inadmissible temperature rise of the insulating joints during welding the open pipe ends of ready to fit insulating joints must not be below the following minimum 100 mm when applying SMAW electronic welding 250 mm when applying OAW autogenic welding 4 5 In order to ensure that the insulating joints can be welded into the pipelines the steel quality of the open pipe ends must correspond to the regulations according to EN 10208 2 4 6 When welding the insulating joints by electric welding the earth contact must be fixed exactly If the earth contact is fixed 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 5 1 General 541 1 For every type of construction or for a modification of the original construction pla
8. protection measures according to 6 2 6 and 6 2 8 must be taken 11 Ge 7 2 2 5 Insulating joints made of steel must be provided with a protective coating by the factory 7 2 2 6 When installing the insulating joints be aware of the shock protection e g exterior coating 7 2 2 7 Each insulating joint must be marked on a visible place with the nominai width DN the nominal pressure PN and the test mark with registration number of an accredited testing agency 7 2 2 8 If necessary insulating joints in HTB design higher thermic capacity 650 C for 30 min must be installed 7 2 3 Test conditions and tests 7 2 3 1 Strength analysis and leakage test In the factory each insulating joint must pass a strength analysis and a leakage test carried out with air under water under a pressure of 1 5 times the nominal pressure but at least 1 bar The test pressure must be maintained for at least 10 minutes In this test the ends must be closed in a way that the axes of the insulating joint are not under pressure In this test leakage is not permissible 7 2 3 2 Electrical test When applying a test alternating voltage of 2000 V at 50 Hz there must not occur break downs or corona discharges the test must last at least 10 seconds The leakage current must not exceed 3 mA When testing with a direct voltage of 500 V in dry conditions the electrical resistance of the insulating joint must not be less than 100 MQ 8 Barrier fitti
9. ready to fit insulating joint with integrated ring spark bridge Various kinds of ready to fit 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 bar Schematic description of overvoltage protection devices on insulating joints Barrier fittings with integrated insulating joint for operating pressures of up to 4 bar Examples for the different kinds of barrier fittings with integrated insulating joint for operating pressures of up to 4 bar Example for an insulating joint for the installation into control and measurement lines Ready to fit Insulating flange pair Insulating flange pair with overvoltage protection device Testing an insulating joint by measurement of the voltage drop Testing an insulating joint by measurement of the electrical field Surge arrester in the measuring box Simplified circuit diagram valve station or similar installations no insulating joint in the main line Simplified circuit diagram valve station or similar installations insulating joint in the main line Lead in of a pipe into a building Insulating joints in house connection line house connection line made of stee No insulating joint in house connection line house connection line made of PE Insulating joint in house connection line house connection line made of PE transition to steel before wall entrance No insulating joint in house
10. 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 a leakage test must be carried out with air under a pressure of at least 5 bar for a period of at least 10 minutes before self polishing In this test leakage is not permissible Electrical test 10 6 34 6 3 5 6 3 6 6 3 7 7 Tat 7 2 7 2 1 7 2 2 7 2 2 1 7 2 2 2 7 2 2 3 7224 Ge Each insulating joint must be tested in dry conditions with a minimum voitage of 5000 V 50Hz for 1 minute During the test there must not occur a corona discharge or an insulation failure The maximum leakage current at 5000 Volt 50 Hz depends on the capacity of the relevant insulating 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 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 least 100 MQ must be achieved Exterior coatings made in the factory must pass resist a non porosity test with an alternating voltage of 25 000 V The results of the non porosity test of the exterior coating can also be integrated in the test certificate of the insulating joint The confo
11. the exterior house wall house connection line made of steel or PE with transition to steel before the inlet into the box case No insulating joint in control box and or meter case at or in the exterior house wall house connection line made of steel or PE transition to steel immediately at the inlet into the box case 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 Steel lines on bridges interruption of the cathodic protection in bridges through installation of insulating joints basic scheme 22 LEGEND Go 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 23 FE A ain na Dimension C according to 5 212 5 213 6 2 12 6 2 13 zv bual coakag E Ni Abe L REA ang nna spark budge uu Kesh T op anat Afp ahur chamber Installation options free welding end a 150 mm both sides welded extensions free pipe end at both sides flange extensions electric welding b gt 100 mm one side flange one side welded extension oxyacetylene welding b gt 250 mm
12. If the insulating joint is placed in an 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 joint also has to be explosion proof When using insulating joints with an integrated spark bridge the corresponding proofs according to 5 2 5 5 2 6 and 5 2 8 must be presented except the demand that the operating voltage must not exceed half of the test voltage Only insulating joints 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 material on the basis of phenonol resin strengthened with paper or reinforced paper serves as insulating material In piggable lines the inside diameter of the insulating ring must have the same size or must be up to at most 3 mm smaller 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 5 2 14 5 2 15 5 2 16 5 2 17 5 2 18 5 2 19 5 2 20 5 2 21 5 2 22 5 3 5 3 1 5 3 3 GoG O ring seals with regular roundings are recommended as sealing material The sealing rings must be placed on appropriate drop shaped grooves or grooves in another shape that are found in the meta
13. ccurs in the underground Installation of insulating joints into buried pipelines according to chapter 5 without illustration Installation of insulating joints into gas pressure regulators and into valve stations according to chapter 5 fig 14 to 16 and 23 to 31 Installation of insulating joints into measurement and control lines according to chapter 5 fig 8 Installation of insulating joints into pipelines on bridges according to chapter 5 fig 32 Location and installation of measuring cables when installing insulating joints Each installed 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 If measuring cables must be buried only double insulated cables are permissible Measuring cables must not have a meta sheath and cores must not be marked with green and yellow Moreover they must have a 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 uO Therefore the connections of the measuring cables should be manufa
14. connection line house connection line made of PE wall entrance unit Insulating joints in buried supply pipe Insulating joint in buried supply pipe partly laid in pipe channel Insulating joints in detached control box and or meter case made of metal or concrete foundation made of reinforced concrete at Fig Fig Fig Fig Fig Fig Fig Fig Fig 24 25 26 27 28 29 30 31 32 EGG Insulating joints in detached contro box and or meter case made of metal or concrete foundation made of reinforced concrete house connection line made of PE transition to steel before inlet into the box case insulating joints in detached control box and or meter case made of metal or concrete foundations made of reinforced concrete house connection line made of PE transition to steel immediately at the inlet into the box case insulating joints in detached control box and or meter case made of plastic foundations made of plastic 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 before inlet into the box case 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 stee immediately at the inlet into the box case Insulating joint in control box and or meter case at or in
15. correspond to EN 10208 1 6 1 4 When producing the insulating joints a quality status corresponding to EN 729 1 and EN 729 2 must be observed while welding 6 2 6 2 1 6 2 2 62 3 6 2 4 6 2 5 626 6 2 7 6 2 8 6 29 6 2 10 6 2 11 6 2 12 6 2 13 o Gr 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 Construction requirements The calculation of the parts under pressure must be based on a load factor of at least S 1 8 The customer has to specify the desired steel quality of the weiding ends The maximum CEV carbon equivaient must correspond to the regulations according to EN 10208 2 Generally the welding ends of insulating joints have to be designed corresponding to EN 10208 2 table 10 The insulating joints must be designed for a minimum temperature range of the medium of 10 C up to 50 C Differing temperatures have to be specified by the customer In order to exclude damage to the inner seal 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 flash over must not affect the imperviousness of the insulating joint In order to protect an insulating joint against flash overs owing to lightning and hi
16. ctured by welding soldering or special thermit welding procedures Adhesive procedures or connections by clamps are to be avoided In no case may the measuring cables may be installed on the insulating joint itself or directly on the round weld distance from the weld at ieast 100 mm 19 2 9 2 10 Go Gr Electrical connections on the surface of the pipes must be manufactured by a welding procedure that does not alter the qualities of the materiai When applying 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 pipe surface the connection method as well as the welding can only be 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 coated 20 Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 Fig 8 Fig 9 Fig 10 Fig 11 Fig 12 Fig 13 Fig 14 Fig 15 Fig 16 Fig 17 Fig 18 Fig 19 Fig 20 Fig 21 Fig 22 Fig 23 GY Gn Annex 2 Illustrations informative The following illustrations are basic examples and are not complete General structure of a
17. e fitted in the factory must be disassembled before welding it into the pipeline in order to avoid the destruction of the insulating and sealing material For the insulating parts of the insulating flange pair a composite layer materia with high compressive strength and good dielectrical qualities must be used The material for the pressure loaded parts must comply with the EN 10208 The insulating flange pairs must be sealed by fiat sealings or O ring sealings The insulating flange pair must be designed for a 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 sea parts of the insulating flange pair 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 flash over must not affect the imperviousness of the insulating flange pair To protect an insulating flange pair against flash overs owing to lightning and high tension interactions an overvoitage protection device with a maximum operation impulse voitage according to the half of the test voltage withstand alternating voltage of the insulating flange pair and with a leakage impuise current of 50 kA waveform 10 350 us corresponding to IEC 1024 1 and IEC 1312 1 must be provided The overvoltage protection device should be fixed directly on the insulating joint
18. e test pressure must be maintained for at least 10 minutes When applying a test aiternating voltage of 2000 V at 50 Hz there must not occur break downs or corona discharges The test must last at least 1 minute The leakage current must not exceed 3 MA When testing with a direct voltage of 500 V in dry conditions the electrical resistance of the insulating joint may not be tess than 100 MQ Ready to fit insulating fiange joints General The insulating flange joint is an electrically insulating non positive flange joint that is pre fitted in the factory The pressure class of the insulating flange only depends on the pressure class of both flanges For every type of construction or for a 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 and presented to the customer Insulating flange joints 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 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 of this line is tested When installing the insulating flange joint be aware of the shock pr
19. essure test the insulation 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 least 100 MQ must be achieved 5 3 4 Exterior coatings made in the factory must pass a non porosity test with an alternating voltage of 25 000 V 5 3 5 The resuits of the non porosity test of the exterior coating can also be integrated in the test certificate of the insulating joint 5 3 6 The conformity with the desired qualities and the data corresponding to 5 2 22 have to be attested according to EN 10204 with an acceptance test certificate 3 1 A or 3 1 C 5 3 7 When using steel qualities with a yield point of gt 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 6 1 General 6 1 1 For every type of construction or for a modification of the original construction plan a prototype testing by an authorised testing agency accredited testing laboratory must be proved 6 1 2 The components of the insulating joint must be tested The test results must be proved in writing and presented to the customer 6 1 3 Insulating joints destined for installation into gas pipelines made of steel must be designed to resist the nominal pressure of the line and must
20. gh tension interactions an overvoltage protection device with a maximum operating impulse voltage according to haif of the test voltage withstand alternating voltage of the insulating joint and with a leakage impulse current of 50 kA waveform 10 350 us 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 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 length of the loop To be efficient the overvoltage protection device must be connected with the insulating joint with a maximum connection inductance of 0 3 uH This can be obtained by using a 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 16 mm Cu according to IEC 1024 1 If the insulating joint is placed in an 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 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
21. he inner seal 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 flash over must not affect the imperviousness of the insulating joint in 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 the half of the test voltage withstand alternating voltage of the insulating joint and with a leakage impulse current of 50 kA waveform 10 350 us 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 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 length of the loop To be efficient the overvoltage protection device must be connected with the insulating joint with a maximum connection inductance of 0 3 uH This can be obtained by using a 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 16 mm Cu according to IEC 1024 1
22. ing kinds of connections are permitted welding end cutting or clamp ring screwing thread These insulating joints need not be coated inside When installing these insulating joints be aware of the shock protection e g exterior coating To prevent damage to the inner seal parts caused by to lightning or high tension interactions construction measures of the insulating joints must ensure the overvoltage protection The interior creep distances and air gaps must be twice as long as the shortest exterior creep distance The thickness of the insulating material must be at least 8 mm Each insulating joint must be marked on a visible place with the following information manufacturer and or registered trade mark nomina width DN and nominal pressure PN type designation If a test mark of an accredited testing agency is available the marking mentioned above is unnecessary when the registration number is engraved and the registration certificate is handed over All qualities must be proved in writing A test mark of an accredited testing agency is equivalent Test conditions and tests a3 9 3 1 9 3 2 9 3 3 10 10 1 10 1 4 10 1 2 10 1 3 10 1 4 10 1 5 10 1 6 10 1 7 10 1 8 10 2 10 2 1 10 2 2 Go Gr In the factory each insulating joint must pass a strength analysis and leakage test carried out with air under water under a pressure of 1 5 times the nominal pressure Th
23. ity of a pipeline Ready to fit insulating fiange joint A ready to fit insulating flange joint is a factory produced ready to fit flange joint that functions as an insulating joint due to is special construction Insulating flange pair An insulating flange pair is a factory produced insulating flange joint that must be taken apart when it is welded into the gas pipeline Barrier fitting with integrated insulating joint A barrier fitting with integrated insulating joint is a structural component of a pipeline that unites the function of the barrier fitting and the insulating joint Creep distance A creep distance is the shortest distance on the surface of insulating parts between the conducting parts Air gap An air gap is the shortest distance in the air between conducting parts Test alternating voltage A test alternating voltage is the effective value of an alternating voltage applied during the test period at a certain frequency Gap section A gap section is the smallest thickness of the insulating material between the parts that have to be separated electrically Overvoltage protection device An overvoltage protection device is an installation for the protection of the electric equipment and systems against inadmissibie high overvoltage Spark gap A sparkgap is the distance between electrically conducting parts that is bridged by arcs in case of electric flash over Spark bridge GY Gp A spark bridge
24. linear electrical conductivity of a metal pipeline The insulating joint is used for demarcation of cathodic protection areas interruption of pipe current flows e g stray currents geomagnetic currents local limitation of inductive influences shock protection prevention of the gas pipeline becoming an earth line separation of metal pipelines made of different material or covered with different sheaths The installation of insulating joints may be required in the following cases in metal pipelines for the electrical separation of line 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 if these have to be separated electrically from the pipeline in control 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 reliably their mechanic and electrical qualities Gn 3 Terminology 3 1 3 1 1 3 2 3 3 3 4 3 5 3 6 3 6 1 3 6 2 Electrical insulating joint Insulating joint The insulating joint is a factory produced ready to fit pipeline element that can t be taken apart and that serves for the interruption of the electric linear conductiv
25. llic materiai Underground insulating joints must suitably be coated or wrapped Above ground insulating joints may be coated with a non conductive materia beware of shock protection The external coating and primer must be compatibie Factory coated insulating joints with welding ends must have an open uncoated pipe end of at least 150 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 as well as the bearing surface of the screw 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 a PE or EP coating preceding sandblasting is absolutely necessary or a 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 a distance of 150 mm from both weiding ends In insulating joints with flange connection 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 serial number or acceptance number nominal width DN nominal pressure
26. 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 length of the loop To be efficient the overvoltage protection device must be connected with the insulating joint with a maximum connection inductance of 0 3 uH This can be obtained by using a maximum loop length of 300 mm or other line feeds with low impedance e g co axial cables drilled lines 17 11 2 10 112 11 11 3 1 11 3 2 11 3 3 EG etc whose total inductance does not exceed 0 3 pH and is resistant to high lightning current at least 16 mm Cu according to IEC 1024 1 If the insulating flange pair is placed in explosive gas atmosphere a surge arrester with the respective licensing corresponding to EN 50014 must be used n this case it is important to consider that the connection an the insulating flange pair also 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 acceptance number nominal width DN and nominal pressure PN mark of the testing agency or of the tester Test conditions and tests Strength analysis and leakage test The strength and the imperviousness of insulating flange pairs does not need to be tested in the factory Electrical
27. n a prototype testing by an authorised testing agency accredited testing laboratory must be proved 512 The components of insulating joints must be tested The test results must be proved in writing and presented to the customer 5 1 3 Insulating joints destined for installation into gas pipelines made of stee must be designed to resist the nominal pressure of the line and must correspond to EN 10208 2 5 1 4 When producing the insulating joints a quality status corresponding to EN 729 1 and EN 729 3 must be observed 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 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 5 2 6 527 5 2 8 5 2 9 5 2 10 5 2 11 5 2 12 5 2 13 CoG Construction requirements The calculation of the parts under pressure must be based on a load factor of at least S 1 8 The customer has to specify the desired steel quality of the welding ends The maximum CEV carbon equivalent must correspond to the regulations according 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 10 C up to 50 C Differing temperatures have to be specified by the customer In order to exclude damage to t
28. ngs with integrated insulating joints for operating pressures of up to 4 bar 8 1 General 8 1 1 Insulating joints that are integrated in barrier fittings must be licensed by an accredited testing agency 82 Construction requirements 8 2 4 When insulating joints are integrated in barrier fittings the latter must be marked e g with a red ring on that side where the insulating joint is placed It can also be marked with a red cap or a similar sign 8 2 2 When the barrier fittings have a HTB design with integrated insulating joint also the insulating joint must have a HTB design 8 2 3 For the rest all the requirements of 7 2 2 shall apply 12 8 3 9 9 1 9 2 9 2 1 9 2 2 9 2 3 9 2 4 9 2 5 9 2 7 9 2 9 9 3 Go Gr Tests Barrier fittings with integrated insulating joints have in addition to the test of the fitting to be tested according to 7 2 3 1 and 7 2 3 2 This shail apply for HTB designs Insulating joints for control and measuring lines General This sector only applies for factory produced ready to fit insulating joints with a nominal width lt DN 25 When insulating joints must be installed in measuring and control lines gt DN 25 those described in sector 5 6 7 or 8 must be used When connecting with cutting or clamp ring screwing these must not be tested Construction requirements Insulating joints must be designed to resist at least the nominal pressure of pipeline The follow
29. of steel A 4 sud L 1g l perface om ie i CE Fig 19 Insulating joint in house connection line house connection line made of PE transition to steel before wall entrance NN ahas 4 L a A VL a Eo r Fig 20 No insulat ing joint in house connection line house connection line made of PE wall entrance unit M Le MMO MMOD AY PAU errance irf aa SICA Y 7 m Go Gr Fig 21 Insulating joints in buried supply pipe NG SS 7 SON css MNOS NY UA Seel Vi Steel Dr SEE Wd NN ae VN MMMM v d EG Fig 22 Insulating joint in buried supply pipe partly laid in pipe channel Stee Steel K mg 45 Eo r ade of m ed concrete ntrol box and or meter case ete foundation made of reinforc tal or concri Fig 23 Insulating joints in detached col me in detached control box and or meter te foundation made of reinforced con made of PE transition to steel befor tal or concre GG ched control box an ched contr lati ing joints in deta stic foundations made of plastic of box and or E Gn ntrol box and or meter case ection line made of steel or Fig 30 No insulating joint in co house wall house conn Go Gr Fig 31 Insulating joint in control box and or meter case at or in the
30. otection e g exterior coating After the pneumatic and leakage test of the pipeline the electrical insulating capacity of the insulating flange joint must be tested according to fig 11 and 12 Construction requirements The ready to fit insulating flange joint generally consists of two pre welded flanges insulating parts disks and cases bolts nuts shims sealings welded pipe parts or flanges The non productive insulating flange joint that is pre fitted in the factory must be installed into the pipeline without disassembly a 10 2 3 10 2 4 10 2 5 10 2 6 10 2 7 10 2 8 10 2 9 10 2 10 10 2 11 10 2 12 10 2 13 10 3 10 3 1 CoC For the insulating parts of the insulating flange joint a composite layer material with high compressive strength and good dielectrical qualities must be used The material for the pressure loaded parts must correspond to the EN 10208 The insulating flange joints must be sealed by flat sealings or O ring sealings The customer has to specify the desired stee quality of the welding ends The welding ends have 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 50 C Differing temperatures must be specified by the customer To prevent damage to the inner seal parts of the insulating flange joints owing to lightning or high tension interactions app
31. rester 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 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 serial number or acceptance number nominal width DN and nominal pressure PN mark of the testing agency or of the tester When using pipe parts that are welded on both sides also the steel quality 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 5 minutes In this test the ends must be closed in a way that the axes of the insulating flange joint are not under pressure 15 10 3 2 10 3 3 10 3 4 10 3 5 10 3 6 10 3 7 11 11141 11 1 2 11 4 3 exon The procedure of the strength analysis can be agreed between the customer and the manufacturer Leakage test After the water pressure test a leakage test must be carried out with air under a pressure of 5 bar for a period of at least 10 minutes before seif polishing In this test leakage is not permissible Electrical test Each insulating flange joint must be tested in dry conditions with a minimum voltage of 5000 V 50HZz for 1 minute During the te
32. rmity with the desired qualities and the data corresponding to 6 2 22 have to be attested according to EN 10204 with an acceptance test certificate 3 1 B When using steel qualities with a yield point of gt 360 N mm 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 Insulating joints for operating pressures of up to 4 bar7 Insulating joints for underground installation For underground installations only insulating joints for operating pressures of over 4 bar may be used according to sector 5 or 6 Insulating joints for exclusively above ground installation General These insulating joints must be licensed by an accredited testing agency Construction requirements Insulating joints lt DN 65 can have fianges weld or and other metallic connections Insulating joints gt ON 65 must not 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 appropriate 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 the insulating joint In those areas where overvoltage is possible overvoitage
33. ropriate 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 the insulating flange joint in order to protect an insulating flange joint against flash overs owing to lightning and high tension interactions an overvoltage protection device with a maximum operating impulse voltage according to half of the test voltage withstand alternating voltage of the insulating flange joint and with a leakage impulse current of 50 kA waveform 10 350 ps 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 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 length of the loop To be efficient the overvoltage protection device must be connected with the insulating joint with a maximum connection inductance of 0 3 uH This can be obtained by using a 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 pH 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 a surge ar
34. st 150 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 as well as the bearing surface of the screw 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 a PE or EP coating preceding sandblasting is absolutely necessary or a 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 a distance of 150 mm from both welding ends In insulating 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 serial number or acceptance number nominal width DN nominal pressure PN steel quality of the 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 nominal pressure for at least 1 minute In this test the ends must be closed so that
35. st there must not occur a corona discharge or an insulation fault The maximum leakage current at 5000 Volt 50 Hz depends on the capacity of the relevant insulating flange joint type size nomina 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 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 least 100 MQ must be achieved External coatings made in the factory have to resist a non porosity test with an alternating valtage 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 flange joint The conformity with the desired qualities and the data corresponding to 10 2 13 must be attested according to EN 10204 with an acceptance test certificate 3 1 B 3 1 A or 3 1 C for pressures of over 16 bar When using for the open pipe ends steel qualities with a yield point of gt 360 N mm an acceptance test certificate 3 1 A or 3 1 C according to EN 10204 is required for the pipe material Insulating flange pairs General The insulating flange pair is an electrically insulating non positive flange joint that is pre fitted in the factory and must be taken apart in order to weld it into the gas pipeline The press
36. test When applying a test alternating voltage of 5000 V at 50 Hz there must not occur break downs or corona discharges The test must last at least 1 minute The leakage current at 5000 V 50 Hz depends on the capacity of the relevant insulating flange pair type size nominal width 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 and the data corresponding to 11 2 must be attested according to EN 10204 with an acceptance test certificate 3 1 B 3 1 A or 3 1 C for pressures of over 16 bar 18 14 1 2 1 3 14 1 5 24 2 2 2 3 24 25 26 27 28 EE Annex1 Arrangement and installation examples of insulating joints The installation of insulating joints into vertical line sections is preferred so that an electrical bridge by conductive foreign elements inside the insulating joint will not occur Installation 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 into 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 lines made of plactic when the transition to lines made of steel o
37. ure 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 an authorised testing agency accredited testing laboratory must be proved 16 1114 11 1 5 11 1 6 1117 11 18 11 2 1 11 2 2 11 2 3 11 2 4 11 2 5 11 2 6 11 2 7 11 2 8 11 2 9 Eo Ge 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 stee must according to their pressure class correspond to EN 10208 and must be designed to resist the nomina pressure of the line When the test pressure of the line does not exceed the test pressure of the insulating flange pair the latter can also be installed into the line before the pressure of this line is tested When installing the insulating flange pairs be aware of the shock protection e g exterior coating After the pneumatic and leakage test of the pipeline the electrical insulating capacity of the insulating flange pair must be tested according to fig 11 and 12 Construction requirements The ready to fit insulating flange pair generally consists of two pre welded flanges insulating parts disks and cases bolts nuts shims sealings The insulating flange pair that is pr
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