Division

Oil States Industries, HydroTech

GPS-24-01
General Product Specification for
Pipe Insulating Joint (PIJ)

1
0
A

Revision
Issue for Use
Issue for Review and Comment

28-July-98
01-May-97
22-Apr-98

GRD
GRD
JEG

ODT
ODT
JEG

LAD
LAD
JEG

Rev

Origination ( 0 ) Revision ( )

Date

Prepared

Reviewed

Approved

Oil States Industries, HydroTech

Division
Date: 28-July-98

Pipe Insulating Joint

GSP-24-01

Rev: 1
Page 2 of 5

General Product Specification, GPS-24-01, defines the specifications for HydroTech systems
standard Pipe Insulating Joints. Pipe Insulating Joints with alternate requirements can be designed
and manufactured but are outside the scope of this document, although this Specification may be
referenced in part.
1. GENERAL DESCRIPTION
A Pipe Insulating Joint (PIJ), illustrated in Figure 1, is a high resistance monolithic or monoblock
fitting used to electrically isolate sections of a pipeline. The primary purpose of electrical isolation is
to improve the effectiveness of cathodic protection systems and to reduce ground loop currents.
Unlike insulating flanges or flange kits which are usually field assembled and tested, the PIJ is
factory assembled, electrical tested at five different stages of manufacturing and hydrostatically
tested. The PIJ is provided with Extension Nipples, matching the pipeline wall and grade, of
sufficient length to eliminate any possibility of thermal damage to the Fitting during field welding.
The monolithic design of the PIJ results in a pipe fitting having high cyclic bending strength
integrity. This aspect is particularly important for offshore pipeline riser applications where cyclic
loading is common. The integrity of the PIJ is further enhanced by the use of high temperature
fluorocarbon (Viton) seals and insulation of high pressure glass filled structural epoxy laminate.
The clean monolithic profile will not trap moisture and reduces the possibility of crevice corrosion.
This is an additional advantage of the monolithic design over conventional insulating flanges in
offshore pipeline applications.
HydroTech Systems maintains an inventory of Pipe Insulating Joints up to 900 ANSI ratings in
nominal sizes from 4 inch to 8 inch with schedule 80 bores and API 5L Grade B pipe Extension
Nipples. Pipe Insulating Joints can be designed and manufactured for any size pipeline.
2. DESIGN REQUIREMENTS
Pipe Insulating Joints designed to this General Product Specification are in accordance with the
ASME Pressure Vessel Code, Section VIII, Division 1, unless another recognized code is specified
by the purchaser. A PIJ is designed to be at least as strong as a comparable rated pipeline when
subjected to external loads.
The electrical resistance, leakage current and breakdown voltage is a function of the insulating
material, insulator thickness and capacitance. The electrical resistance of the PIJ is at least 40
megohms with 1000 VDC applied potential and the maximum leakage current, with 2500 VAC (60
Hz) applied potential, is 5 mA. The dielectric strength (breakdown voltage) of the PIJ is designed
to be in excess of 20,000 volts.

Oil States Industries, HydroTech

Division
Date: 28-July-98

Pipe Insulating Joint

GSP-24-01

Rev: 1
Page 3 of 5

3. MATERIALS AND COATINGS

Standard materials for Pipe Insulating Joints are tabulated below along with the appropriate
HydroTech Material Specification (HMS). The appropriate standard material for a particular PIJ
End Flange, Retainer Flange and Hub is based on the matching pipeline material grade. The PIJ
Assembly is externally protected by three coats of high build epoxy per HydroTech Coating
Specification, HCS-4. Bare internal surfaces and butt-weld preparations are coated with a
temporary rust preventive per HCS-6.
Component

Material
ASTM A105 (HMS-1) for matching pipe
grades up to and including API 5L-X42
End Flange
ASTM A694 Gr F46 or Gr F52 (HMS-16,
CL 1 or 2) for matching pipe grades above
API 5L-X42
ASTM A105 (HMS-1) for matching pipe
grades up to and including API 5L-X42
Hub
ASTM A694 Gr F46 or Gr F52 (HMS-16,
CL 1 or 2) for matching pipe grades above
API 5L-X42
ASTM A105 (HMS-1) for matching pipe
grades up to and including API 5L-X42
Retainer Flange
ASTM A694 Gr F46 or Gr F52 (HMS-16,
CL 1 or 2) for matching pipe grades above
API 5L-X42
API 5L-Grade to match pipeline
wExtension Nipples
Insulator Rings
Glass filled epoxy laminate, NEMA Gr G10
Insulation Epoxy
Aluminum oxide filled resin
O-Ring Seals
Molded Viton (HMS-14)
wWhen the pipeline has an uncommon wall thickness, grade or special material requirements, pipe
for the Extension Nipples intended to match the pipeline, must be supplied by the purchaser.
4. QUALITY ASSURANCE
The part and heat number of each PIJ End Flange, Hub, Retainer Flange and Extension Nipple
are steel stamped. Each Assembly also has a unique serial number stamped on the outside
diameter of the Retainer Flange for complete material traceability. Dimensional inspection
reports and material test reports for each component are maintained on file.
The welds to the Extension Nipples are 100% radiographically examined per ASME Section
VIII, Division 1, Part UW-51 and the End Flange-to-Retainer Flange weld is ultrasonically

Oil States Industries, HydroTech

Division
Date: 28-July-98

Pipe Insulating Joint

GSP-24-01

Rev: 1
Page 4 of 5

examined per ASME Section VIII, Division 1, Appendix 12.

In accordance with HydroTech Quality Assurance Procedure, HQA-496, the insulating
characteristics of each PIJ is tested before welding, after welding and after injecting with epoxy.
Each PIJ is then hydrostatically tested to 1.5 times the design pressure for a minimum of 1 hour
and the insulating characteristics are tested twice more per HydroTech Quality Assurance
Procedure, HQA-489. The final two tests of the insulating characteristics are conducted after
hydrostatically testing and finally after coating.
Upon request, up to two sets of Quality Assurance documentation will be provided for all Pipe
Insulating Joints. The documentation shall consist of the following:

Certificate of Conformance
Material Test Reports for pressure containing components
NDE Reports for radiography of welds
NDE Report for ultrasonic examination of weld
PIJ Epoxy Injection Procedure, HQA-496
Acceptance Test Procedure, HQA-489, and Test Chart
Heat Sketch for each pressure containing component identifying:
Part number
H number (traceable to vendor heat number)
Serial number
HydroTech purchase order number
HydroTech sales order number

5. ORDERING INFORMATION
The following minimum information must be specified on any request for quotation or purchase
order for a PIJ intended to meet this General Product Specification, GPS-24-01.
Nominal pipe size
Pipe wall thickness or bore
Pipe grade
Design rating
Revision Record
Revision #
1

Date
July 1998

Page
Page 2, Section 2,
Second Paragraph

Revision Detail
Replace 5000 with 2500

Oil States Industries, HydroTech

Division
Date: 28-July-98

Pipe Insulating Joint

GSP-24-01

Rev: 1
Page 5 of 5