Alternative to Flanged Isolation Kits and Joints
Factory Assembled Under Controlled Conditions.
Tube Turns insulated joints are prefabricated, one-piece unions of butt-weld, forged body construction used to electrically isolate and protect pipe work and associated equipment from corrosion damage caused by stray electrical currents and unwanted electrical potentials that come to the pipeline from overhead power lines, parallel pipelines and other sources.
Isolation Joints prevent metal to metal contact across the joint; and this protection is long term and maintenance-free. Custom built to your specifications, Isolation Joints are manufactured to any diameter or wall thickness and are through-bored to allow for the passage of pigs and scrapers; and each Isolation Joint is serialized, heat code identified and traceable.
Tube Turns Pipe Pup Insulated Joints have these advantages over other electrical isolation devices:
1. Fully factory assembled and ready for installation, no need to disassemble or reassemble
2. Factory tested electrically
3. Factory inspected and mechanically leak tested
4. Internally and externally coated with non-conductive epoxy at the factory
5. Requires no maintenance or adjustment after installation
6. Structurally robust
Monolithic isolation joints shall be bolt less and completely factory assembled in accordance with the appropriate requirements of ASTM, API, DIN and BS codes. All welds shall be butt weld construction. The dielectric isolation material shall be a high temp thermosetting fiberglass epoxy material. Sealing shall be by dual static, self energized “O” ring seals housed in accurately machined grooves, fully protected from cavitation in full compliance with ASME design codes. Interior and exterior coating shall be a two part epoxy with a thickness of .016 to .024” (.40-.60mm) to within 2” of each end. Each unit shall be tested for Electrical (@5kv, 25 Mohm), Hydrostatic (@ 1.5 x O.P.) and Weld (Ultrasonic/Magnetic Particle).
· Designed for use with almost any fluid: oil, gas, water
· Onshore, offshore, buried, aboveground or subsea; in “sweet” (non-corrosive) or “sour” corrosive applications
· High pressure gas transmission service
· Gas gathering systems
· Liquid pipelines of all types
· Gas distribution and branch lines
· Anywhere the pipeline enters or exits the ground
· Installed on inlet and outlet pipes to isolate meters, tanks, pump and compressor stations from the main CP system
Benefits of Monolithic Construction:
· Boltless monolithic design is maintenance-free (eliminates bolted connections)
· Fully tested to verify mechanical integrity and electrical resistance (hydrostatically, electrically and weld tested)
· Coated internally and externally w/non-conductive two-part epoxy resin coatings of different types
· Engineered to Order: custom built to your specifications: same metallurgy, yield strength, WT as matching pipe
· Hubs of Dual Certified or Triple Certified: ASTM A694-F52/ASME SA105 or SA350 LF2 CL1; higher yield mat’l available
· Each insulated joint is traceable, serialized and heat code identified
· Certified Material Test Reports (MTRs) furnished on all pressure containing metallic components
· Made in the US at our ISO Certified ASME facility in Louisville, KY
· Standard 8-week delivery
Quality and Standards
Insulated joints are produced under ISO 9001-2008 certification, and comply with these standards (as applicable):
Materials: ASTM, AWS, ASME IX, ASME II, Part C NDE Examinations and Inspections: ASME V, ASME/ANSI B 31.3, ASME/ANSI B 31.4, ASME/ANSI B 31.8, ASME Section VIII, Div. 1, API 1104 All metallic components are supplied with certified Material Test Reports (MTRs), confirming the physical and chemical properties of the components.
Monolithic Insulated Joints - Isolation Joints
Application
Tube Turns Monolithic Insulated Joints electrically isolate sections of pipeline to prevent corrosion caused by stray electrical currents or interference from other pipelines and power transmission cables.
TUBE TURNS® Monolithic Insulated Joints electrically isolate sections of pipeline to prevent corrosion caused by stray electrical currents or interference from other pipelines and power transmission cables. Three features assure electrical isolation:
- Insulating gasket that prevents metal-to-metal contact across the joint
- Internal cavities filled with a special dielectric compound
- Internal and external surfaces coated with two (2) coats of non-conductive epoxy paint, or coating per the customer’s specification.
Sizes
Insulated Joints (also referred to as “Isolation Joints” or “Insulating Joints”) are available in sizes ranging from 2" thru 48" and pressure ranging from ANSI 150 to ANSI 900. Available with "Pipe Pups".
Construction
Tube Turns’ Monolithic Joints feature a pre-fabricated, non-separable, and bolt-less design to satisfy customers that require a single-piece construction for simplicity of installation, elimination of maintenance, and ease of final wrapping and coating after installation in the pipeline. Pressure Fatigue, Torsion and Bending proof testing of the design was carried out to provide a design that is physically stronger than the pipe to which it is attached.
Testing
Each joint manufactured by Tube Turns is completely factory assembled and hydro-statically tested to 1.5 times the working pressure before shipment. In addition, each joint is electrically tested to verify its insulating capability. No maintenance required for the entire service life of the insulating joint.
Coatings
- Standard two part epoxy (Akzo Nobel)
- Denso Protal 7200
- Others available to meet customer spec
Manufactured In The USA
Tube Turns Products manufactures all of its products at its facilities in Louisville, Kentucky, USA
“W” Series Monolithic Insulated Joint Specification
Pipeline Insulated Joint Design Codes and Standards
- ASME B31.4 Liquid Petroleum Transportation Piping Systems
- ASME B31.8 Gas Transmission and Distribution Piping Systems
- ASME BPVC Sec VIII Div. 1 and 2
- ASME BPVC Sec II Materials
- ASME BPVC Sec V NDE
- ASME Sec IX Welding
- ASTM applicable material standards (A694)
Isolation Joint Size and Ratings
Size 2 – 42-inch – ASME CL 150 - 900
· ASME CL150 (WP = 285 psi) - hydrostatic test pressure = 450 psi for 15 min (1.5x design pressure)
· ASME CL300 (WP = 740 psi) - hydrostatic test pressure = 1125 psifor 15 min (1.5x design pressure)
· ASME CL600 (WP = 1480 psi) - hydrostatic test pressure = 2225 psi for 15 min (1.5x design pressure)
· ASME CL900 (WP = 2220 psi) - hydrostatic test pressure = 3350 psi for 15 min (1.5x design pressure)
· DF = 0.5 is standard (depends on spec and “Location Class” per B31.4/B31.8)
Pipeline Insulating Standard Welding Hub Materials: ASTM A694/ASME SA105 or SA106 Gr C 52k min yield
· Pipe (2 – 6 inch) SA 106 Gr C 52,000K min yield strength
· Forgings (8-inch +) A694 F52 Dual Certified (52,000 min yield strength) and either SA105 or SA350LF2 CL1
o Or hubs are Triple Certified – SA105/SA350LF2 CL1/A694-F52
o When matching higher yield strength pipe, dia. at weld bevel can be increased to meet piping code requirements such as ASME B31.8 Fig. I5 or higher yield materials can be used; F60, F65, F70
· All material serialized, heat code identified and traceable
· Forged or pipe bodies welded under a compression load (design calcs available)
· Strict limits on Carbon Equivalent (%CE) .045% max or to customer spec
o %CE regards how different alloying elements affect the hardness of steel
Material chemistry impacts weld quality
Gas Pipeline Isolation Joint Mechanical Leak Test
Each Isolation Joint individually Hydrostatically Tested to 1.5 x design pressure (or customer spec)
Gas Pipeline Isolation Joint Electrical Testing:
· Resistance test (std) – able to withstand an applied voltage of 1000 V DC (std is 25 megohm min resistance)
o Most IJs exhibit resistance > 2000 megohms
· Dielectric Strength test (std test to meas. current leakage): 5kV AC @50 Hz for 1 min. (max leakage 5mA)
o A non-destructive test; no data on voltage that would cause arcing; safely say it’s > 5,000 VAC
A test to determine “breakdown voltage” would be a destructive test
ASME Section IX Welding
· All welding done in-house by company certified welders working to written welding procedure specifications
· SMAW, GTAW, GMAW, SAW, ERW
· Full-time welding engineer in-house
Weld Test report (UT) furnished on yoke closure welds
“W” SERIES MONOLITHIC INSULATED JOINT SPECIFICATION
Isolation Joint Data Package Includes:
· Hydrostatic test report (1.5 x design pressure)
· Electrical test report (resistance & withstand)
· Weld test report (UT of closure welds/ends)
· Certified MTRs for all metallic components
· Approval Drwg – when requested (includes SN, Heat #, Size, Class, Materials, Hydrotest pressure, Insulator, Coating)
Design calculations (when requested)
Isolation Joint Insulator (FR4)
· Type FR-4 (Flame Retardant) High Strength Glass Reinforced Epoxy Resin Laminate (GRE)
· Ultra-strong plastic – Ultimate Tensile Strength of 45,000 psi (Cast Iron 29K, Cooper 31K, Alum 45K)
· Min electrical strength 15,000 Volts
· The world’s most commonly used electrical insulator
· Non-hygroscopic, waterproof (Near zero water absorption)
· Highly chemically resistant to a range of hydrocarbons
· Retain its high mechanical values and electrical insulating qualities in both dry and humid conditions
Dielectric filler material is liquid epoxy fills body cavity voids (data sheet available)
FKM O-rings (Internal seals) are:
· Dual static, self-energized FKM/Viton
· Housed in grooves machined into each weld hub
· Under compression and locked into position to provide a positive pressure seal
Completely sealed internally and to atmosphere
Marking – Forging and Pipe Traceability
· Each Isolation Joint is marked by low stress steel stencil on outside of yoke:
- Mfg name
- Serial #
- Pressure Class
- Material Heat #
- Material Heat # also marked on outside of hub
Isolation Joint Bore/Beveled Weld Ends:
· All IJs through-bored to allow passage of pigs and scrapers
Weld ends to match corresponding pipe ends per ASME B16.25, ASME B31.8, API 5L or customer spec
US made at our ASME facility in Louisville, KY
· Made with US steel; Complies with “Buy America” provisions
Standard 8-week delivery after approvals, if required
"Pipe Pup Insulated Joints"
Pipe Pup Isolation Joints
Tube Turns “Pipe Pup” Insulated Joints are monolithic, pre-assembled and tested units used to electrically isolate piping or pipeline segments from adjacent equipment. A key feature of “Pipe Pup” Insulated Joints is the inclusion of ready-to-weld pipe ends matched to the customer’s pipeline outside diameter, internal bore, wall thickness and pipe grade.
Tube Turns “PIPE PUP” Insulated Joints are monolithic, pre-assembled and tested units used to electrically isolate piping or pipeline segments, and from adjacent equipment. A key feature of “Pipe Pup” Insulated Joints is the inclusion of ready-to-weld pipe ends matched to the customer’s pipeline outside diameter internal bore, wall thickness and pipe grade.
Standard designs are carbon steel, with Pipe Pup metallurgy in API 5L Gr. B and hub/yoke metallurgy in ASTM A105. Also available are Yoke and Hub components in ASTM A694 F42, F46, F50, F52, F56, F60, F65, F70
Pipe Pup Insulated Joints are available in ANSI Class 150, 300, 600, 900, 1500, and 2500. Design options are available for temperature ranges from -50°F (-46°C) to 203°F (95°C). Up to 482°F (250°C) available on request.
The weld end hubs of our Insulating joints are provided in compliance with the customer’s piping specification. Optional extra-length pipe pups (provided by the customer) can be included in the completed joint.
Applications
Tube Turns’ Pipe Pup Insulated Joints can be designed for use with almost any fluid, including oil, gas, water, etc. where the operating temperature range falls within -50°F (-46°C) to 338°F (170°C). The insulated joints can be installed vertically, horizontally, or any other orientation, onshore, offshore, buried, exposed aboveground, or subsea, and in “sweet” (non-corrosive) or “sour” (corrosive) applications.
Also Know As
These connections are known in the pipeline industry by various terms such as the following:
- Monolithic Insulating Joint
- Monolithic Insulation Joint
- Monolithic Isolating Joint
- Monolithic Isolation Joint
Pipe Pup Isolating Joint Materials
STANDARD MATERIALS:
- HUB - PIPE NIPPLES API 5L GR X52 PSL-2 AND ISO 3183-3 GR L360 (X52) PSL-2 CERT
- Yoke – A694-F52
- FKM FLUORELASTOMER O-RINGS
TWO PART EPOXY CORROSION COATING FOR EXT & HUMID ENVIRONMENT
HYDRO TEST 5 HRS @ 1.5 TIMES
CARBON EQUIVALENT-0.32,NIOBIUM 1% MAX,SULFUR .002%
Now Offering Pipeline Pig Signalers
The Sypris® Technologies Sig-Tech® intrusive Pig Signaler can be installed at pre-determined intervals on pipelines to detect the passage of a cast polyurethane pigs or spherical type pigs.