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نویسندگان
b) Nominal anode shape and dimensions, and whether a standard or non-standard anode is required.
Note:
The ordering/purchasing documents shall specify required dimensions of anode, steel core, and brackets and net and gross weight of anodes, or alternatively reference shall be made to a supplier’s standard type and size of anode or anode assembly.
c) Design life.
d) Seawater temperature range.
e) Seawater depth.
f) Whether it is the intention of the Purchaser to inspect the anodes at the supplier’s work.
g) Any additional packaging and labeling requirements.
12. PACKING AND SHIPMENT
12.1 Anodes shall be packaged to provide adequate protection during shipment, handling and transportation. Cleaning, preservation, and packaging of anodes shall be in accordance with the manufacturer’s commercial practice, provided that they are such as to ensure acceptance by common or other carriers for safe transportation at the lowest rate to the delivery point.
12.2 When specified in the contract or purchase order, anodes shall be preserved, packaged, and packed in accordance with the requirements of ASTM Practice B 660M. The applicable levels shall be as specified in the contract or order.
13. MARKING
Each pallet shall be plainly marked with the following information:
Name: ................…………………………………………………………………………….…..
Specification: IPS-M-TP-750: Part 6 .....................................………………………….…..
Order No.: .........………………………………………………….………………………….…..
M.E.S.C No.: .....………………………………………………….………………………….…..
Anode type: .......………………………………………………….………………………….…..
Anode weight (net and gross): ................................................………………………….…..
Anode dimensions: ..................................................................………………………….…..
Batch No.: .........…………………………………………………..………………………….…..
Stock No.: ..........………………………………………………….………………………….…..
Date of manufacture: ..........................................................………………………….…..
Quantity (number of anodes): .............................................………………………….…..
Manufacturer’s name and address. ....................................………………………….…..
Note:
Each pallet shall be clearly marked "FRAGILE".
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APPENDICES
APPENDIX A
METHOD FOR THE DETERMINATION OF THE ANODE-TO-CORE
RESISTANCE OF GALVANIC ANODES
A.1 General
This Appendix describes the method for the determination of the anode-to-core resistance of galvanic (sacrificial) anodes used for cathodic protection.
A.2 Principle
The voltage across the anode metal and anode core is measured when a known current is passed between them. The anode-to-core resistance is then computed by dividing the measured voltage by the known current.
A.3 Apparatus
The following apparatus is required:
a) A d.c. supply of 5A capacity, with an adjustable current control capable of smooth variation from 5A to near zero. It shall be capable of generating an on-load-voltage sufficient to pass a current of 5A through a resistance of not less than 1 . Ω
b) An ammeter capable of reading to at least 5A d.c. with a maximum error of ±1% at full scale deflection. This ammeter may be integral with the d.c. supply (see Item (a)).
c) A millivoltmeter of the electrically protected type capable of reading to 50 mV d.c., with a maximum error of ±1%.
d) Suitable test leads and clamps or clips to connect Items (a), (b) and (c) to the anode and the core. The clamp system shall be of such quality to ensure that the connection resistance to each point is less than 0.05 Ω.
A.4 Circuit
The circuit shall be arranged as shown in Fig. A.1. The leads connecting the millivoltmeter to the anode and the anode core, shall be independent of the leads from the power supply. All connections shall be properly made to minimize contact resistance.
If the millivoltmeter is connected across the anode metal and the terminal of the cable attached to the anode core, the anode-to-core resistance is obtained by subtracting the cable resistance from the total resistance. The total resistance is computed by dividing the measured potential by the known current.
A.5 Procedure
The procedure shall be as follows:
a) Before connecting the power supply, set the variable current control to ensure a minimum current flow when the circuit is switched on.
b) Connect the power supply. Adjust the variable current control until approximately 5A is registered on the ammeter.
(to be continued)
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APPENDIX A (continued)
c) Read the voltage difference as indicated by the millivoltmeter.
d) Calculate the anode-to core resistance (R), in ohms, using the following equation:
R = amperes)(in readingammeter (in volts) readingeter millivoltm
e) Reverse both ammeter supply leads and also the millivoltmeter supply leads, and repeat Steps (a) to (d) above. The result of this second calculation of R should be the same as the initial result.
A.6 Report
The test report shall contain the following information:
a) Name of test laboratory.
b) Identification of the equipment used to carry out the test.
c) Identification of the galvanic anode tested.
d) The date on which the test was carried out.
e) The results of the anode-to-core resistance test calculations.
f) Reference to this test method.
SCHEMATIC CIRCUITS FOR MEASUREMENT OF ANODE-TO-CORE RESISTANCE
Fig. A.1
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APPENDIX B
METHOD FOR THE DETERMINATION OF THE CONSUMPTION
RATE OF ALUMINUM ANODE ALLOYS IMMERSED IN SEAWATER
B.1 General
This Appendix describes the method for the determination of the consumption rate of aluminum anode alloys intended for use in cathodic protection of ferrous metals immersed in seawater.
Note:
The anode alloy consumption rate, expressed in kilograms per ampere year, is an important factor when the performance of different alloys for the sacrificial protection of ferrous metal structures in seawater is being assessed. The consumption rate may be used to compute the current capacity of an anode system.
B.2 Principle
The loss of anode mass, which occurs when a known quantity of current flows from the anode to the cathode in seawater, is computed to show the quantity of anode metal consumed in one year by the passage of 1 A.
B.3 Apparatus
The following apparatus is required:
a) A constant current d.c. power supply with an output voltage appropriate to the number of test cells in series, and having sufficient current capacity to maintain the specified anode current density. The output current stability of the power supply shall be within ±1%.
b) An ammeter to suit the current requirement, and having a maximum error of ±1%. This ammeter may be integral with the power supply (see Item (a)).
c) Aluminum cathodes; one per aluminum anode.
d) Non-metallic tanks; one per anode, to hold seawater.
e) Clean seawater with a resistivity of not greater than 0.3Ω .m at 20°C, or synthetic seawater conforming to the requirements of ASTM D 1141.
f) An agitator.
B.4 Circuit
The circuit shall be arranged as shown in Fig. B.1.
B.5 Preparation of Test Anodes
The as-manufactured anode surface is preferred for test purposes, however cut and machined surfaces are not excluded for use in this test. All anodes used in the same test series shall have the same nominal composition and the same area dimensions exposed to seawater.
Any mounting strap or wiring conductor shall be covered to prevent contact with seawater.
(to be continued)
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APPENDIX B (continued)
The anodes shall be cleaned in nitric acid (e20 1420 kg/m³) at ambient temperature and then thoroughly rinsed in clean fresh water and dried.
B.6 Procedure
The anode consumption rate shall be determined as follows:
a) Weigh each anode and record its mass.
b) Connect the circuit as shown in Fig. B.1.
c) Adjust the power supply to produce a current output equivalent to a current density of between 0.5 mA/cm² and 0.7 mA/cm² of anode surface area. Note the time of commencement of the test and the set current value.
d) Change the seawater when 0.1 A.h has passed for each 1 L of seawater in a cell.
e) Continue the test for a period of at least 10 days.
Note:
The longer the test period the more reliable will be the result.
f) Remove the test anodes from the cells. Clean, rinse and dry the test anodes in accordance with Paragraph B.5, and reweight.
g) Calculate the alloy consumption rate for each anode, in kilograms per ampere year, using the following equation:
Alloy consumption rate = flowcurrent total8760 loss mass×
Where:
mass loss is in kilograms;
total current flow is in ampere hours.
Express the result to the nearest 0.1 kg/A.Year.
(to be continued)
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APPENDIX B (continued)
Legend:
C = cathode
A = anode
SCHEMATIC CIRCUIT FOR DETERMINATION OF ALLOY CONSUMPTION RATE
Fig. B.1
B.7 Report
The report shall contain the following information:
a) Name of the test laboratory.
b) Identification of the equipment used to carry out the test.
c) Identification of the anode material.
d) The mass of each anode before and after completion of the test.
e) Other test details including the test period.
f) The dates during which the test was carried out.
g) The test results.
h) Reference to this test method.
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APPENDIX C
METHOD FOR THE DETERMINATION OF THE CLOSED-CIRCUIT
POTENTIAL OF ALUMINUM ANODES IMMERSED IN SEAWATER
C.1 General
This Appendix describes the method for the determination of the closed-circuit potential of aluminum anodes intended for use in the cathodic protection of ferrous metals immersed in seawater.
Note:
The closed-circuit potential, as distinct from the open-circuit potential, is a critical factor when assessing the ability of galvanic anodes to protect ferrous metal structures in service.
C.2 Principle
The closed-circuit potential is measured when current is flowing between an anode and cathode in seawater, by locating a reference cell close to the anode surface.
C.3 Apparatus
The following apparatus is required:
a) A 12 V d.c. power source with a variable resistance to maintain the specified anode current density.
b) A suitable ammeter.
c) A high resistance voltmeter with a minimum input resistance of 1 Ωm/V and a resolution of 10 mV or better, and having a maximum error of ±1% at full scale deflection.
d) A silver/silver chloride or saturated calomel reference electrode.
e) An aluminum cathode.
f) A non-metallic tank to hold seawater.
g) Fixed resistors of equal value. The voltage drop across each fixed resistor shall be at least 10 V.
h) Clean seawater with a resistivity of not greater than 0.3 Ω.m at 20°C, or synthetic seawater conforming to the requirements of ASTM D 1141.
C.4 Circuit
The circuit shall be arranged as shown in Fig. C.1 to enable the testing of one of a series of anodes. All anodes in the circuit shall have the same nominal composition and shape and the same area dimensions exposed to the seawater.
Any mounting strap, wiring conductor or anode connection shall be insulated at the air/water interface to prevent contact with seawater.
C.5 Preparation of Test Anode
For test purposes, it is preferred that the surface of the anode is in the as-manufactured condition, however cut and machined surfaces are also acceptable.
(to be continued)
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APPENDIX C (continued)
C.6 Procedure
The closed-circuit potential shall be determined using the following procedure:
a) Arrange the equipment so that the anode-to-cathode distances are approximately the same, and the current flow is not affected by cell geometry or adjacent anodes.
b) Adjust the test anode current density to a value between 0.5 mA/cm² and 0.7 mA/cm² and record the time of commencement of current flow. Change the seawater when 0.1 A.h has passed for each litre of seawater contained in the tank.
c) Record, to the nearest 0.01 V, the closed-circuit potential on the voltmeter. Continue the test until three consecutive stable readings are obtained at time intervals of 1 h.
d) Report the last three stable closed-circuit potential readings obtained with respect to the reference cell, for the anode under test.
e) Repeat Steps (a) to (d) for each anode tested to enable duplication of the results.
C.7 Report
The report shall contain the following information:
a) Name of the test laboratory.
b) Identification of the equipment used to carry out the test, the reference cell, details of the circuit and details of the seawater used.
c) Identification of the anode material, and number and dimensions of anodes in the circuit.
d) The current density used, test procedure details and resultant closed-circuit potential readings (in duplicate).
e) The date of testing.
f) Reference to this test method.
SCHEMATIC CIRCUIT FOR MEASUREMENT OF CLOSED-CIRCUIT POTENTIAL
Fig. C.1
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APPENDIX D
TYPICAL MASSES AND DIMENSIONS OF PLATFORM ALUMINUM ANODES

All weights and dimensions are nominal.
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APPENDIX E
ALUMINUM ANODES TYPICAL FIXING ARRANGEMENTS
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PART 7
CATHODIC PROTECTION CABLES
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CONTENTS : PAGE No.
1. SCOPE.......................................................................................................................................107
2. REFERENCES...........................................................................................................................107
3. DEFINITIONS AND TERMINOLOGY.........................................................................................107
4. UNITS.........................................................................................................................................108
5. TECHNICAL DOCUMENTS.......................................................................................................108
6. GENERAL CABLE CONSTRUCTION REQUIREMENTS.........................................................109
7. SPECIFIC CABLE REQUIREMENTS........................................................................................111
8. QUALITY ASSURANCE PROVISIONS.....................................................................................112
9. TESTS........................................................................................................................................112
10. INSPECTION............................................................................................................................113
11. CERTIFICATION......................................................................................................................114
12. PACKAGING AND SHIPMENT................................................................................................114
13. LABELING...............................................................................................................................114
14. GUARANTEE...........................................................................................................................115
APPENDICES:
APPENDIX A DATA SHEET FOR CATHODIC PROTECTION CABLE.......................................116
APPENDIX B DATA SHEET FOR CATHODIC PROTECTION CABLE.......................................117
APPENDIX C DATA SHEET FOR CATHODIC PROTECTION CABLE.......................................118
APPENDIX D DATA SHEET FOR CATHODIC PROTECTION CABLE.......................................119
APPENDIX E CABLE DESIGN DATA...........................................................................................120
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1. SCOPE
This part of IPS-M-TP-750 covers the minimum requirements for the materials, construction, dimensions, packaging and tests of cables, intended for DC services in cathodic protection installation for pipelines, well casings, storage tanks, ships and other buried or water-submerged metallic structures.
Appendices A, B, C and D are the data sheets which shall be used for ordering purposes.
2. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These referenced documents shall, to the extent specified herein, form a part of this standard. For dated references, the edition cited applies. The applicability of changes in dated references that occur after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated references, the latest edition of the referenced documents (including any supplements and amendments) applies.
ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)
B8 Standard Specification for
"Concentric-Lay-Stranded Copper Conductors, Hard, Medium Hard or Soft"
D 470 Standard Methods of Testing
"Crosslinked Insulations and Jackets for Wire and Cable"
D 1047 Standard Specification for
"Poly (Vinyl Chloride) Jacket for Wire and Cable"
D 1351 Standard Specification for
"Polyethylene Insulation for Electrical Wire and Cable"
D 2219 Standard Specification for
"Poly (Vinyl Chloride) Insulation for Wire and Cable, 60°C Operation"
D 2308 Standard Specification for
"Polyethylene Jacket for Electrical Insulated Wire and Cable"
D 2633 Standard Methods of Testing
"Thermoplastic Insulations and Jackets for Wire and Cable"
D 2655 Standard Specification for
"Crosslinked Polyethylene Insulation for Wire and Cable Rated 0 to 2000 Volts"
D 3144 Standard Specification for
"Poly (Vinylidene Fluoride) Heat-Shrinkable Tubing for Electrical Insulation"
IEC (INTERNATIONAL ELECTROTECHNICAL COMMISSION)
IEC 228 "Conductors of Insulated Cable"
3. DEFINITIONS AND TERMINOLOGY
Conductor
A wire or combination of wires not insulated from one another, suitable for carrying an electric current.
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Jacket
An integral covering which is applied over the insulation of a cable and whose prime function is to provide mechanical or environmental protection for the component(s) that it covers.
Primary insulation
The first layer of two or more layers of insulating materials over a conductor. Its prime function is to act as an electrical barrier.
Stranded conductor
A conductor composed of a group of wires, usually twisted, or of any combination of such groups of wires.
Wire
A rod or filament of drawn or rolled metal whose length is great in comparison with the major axis of its cross section.
Inspection and testing terms
Lot
A lot is any amount of cable of one type and size presented for acceptance at one time.
Sample
A sample is a quantity of production units (reels) selected at random from the lot for the purpose of determining conformance of the lot to the requirements of this Part of Standard specification.
Sample size
The number of production units taken to make up the sample.
Specimen
A specimen is a length of cable removed for test purposes from any individual production unit of the sample.
4. UNITS
This Standard is based on International System of Units (SI), except where otherwise specified.
5. TECHNICAL DOCUMENTS
5.1 The technical bid shall include the following:
a) Constructional and electrical data for the cable(s) to be offered.
b) Conductor size, number, and diameter of individual strands and overall conductor diameter (mm).
c) Thickness of insulation and jacket (mm).
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d) Normal length of cable on reel (m).
e) Approximate net and shipping weights (kg/km).
f) Maximum DC resistance at 20°C (ohms/km).
5.2 The Manufacturer shall provide upon request a specification sheet indicating:
- Manufacturer’s name.
- Product identification number.
- Construction details.
- Voltage rating of primary insulation.
- Physical properties of the primary insulation and jacket material including tensile strength and ultimate elongation of finished cable, insulation resistance of the primary insulation, notch propagation of the finished cable, abrasion resistance of the finished cable, concentricity tolerance of the finished cable, and continuous service temperature limits of the finished product.
- Test results and test certificates.
6. GENERAL CABLE CONSTRUCTION REQUIREMENTS
6.1 Conductor
The conductors shall be plain annealed stranded copper. Stranding shall be circular (non-compacted).
The material shall be copper of such quality and purity that the finished product shall have the properties and characteristics prescribed in IEC Publication 228 Class 2, or ASTM specification B8 Class B. Conductor sizes, as will be specified by the Purchaser, shall be in accordance with one of the designations listed in Table 1 and/or Appendix E to achieve the resistance value required:
TABLE 1 - CONDUCTOR SIZES

* The actual cross-sectional area is approximately 47 mm².
The size, cross-sectional areas, and direct current resistance of the conductor in the completed cable shall conform the minimum and maximum values allowed by the above referenced standards.
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1.
6.2 Insulation
6.2.1 General
Cable insulation shall be made from materials chemically and physically resistant to the environmental effects to be anticipated in buried or submerged service. It shall provide continuous coverage, adequate dielectric properties, and have a high resistance to abrasion, stress cracking and notch propagation.
The insulation shall be one of the types listed in subclause 6.2.2. The insulation shall be applied tightly to the conductor without adhering to it and shall form a compact and homogeneous body.
The sheath (jacketing) shall be an extruded layer of the types listed in subclause 6.2.2. The sheath shall be continuous having a thickness as uniform as possible and not less than the values specified. It shall be possible to remove the sheath of the cable without damaging the insulation of the conductor.
Cable insulation (primary insulation and sheath) shall be completely free of cracks, nicks, scratches, or other discontinuities.
Cable insulation shall have a voltage rating of 600/1000 Volts in accordance with National Electrical Code.
6.2.2 Insulating materials
The types of insulation and sheath compound covered by this Part of Standard specification are listed below.
6.2.2.1 Polyvinylchloride (PVC)
Insulation and sheath compound based on polyvinylchloride or copolymer of vinylchloride and vinyl acetate conforming to ASTM specifications D 2219 (as Insulation) and D 1047 (as Jacketing).
6.2.2.2 High molecular weight polyethylene (HMWPE)
Insulation and sheath compound based on thermoplastic polyethylene conforming to ASTM specifications D 1351 (as Insulation) and D 2308 (as Jacketing).
The polyethylene before application to the conductor (or cable) shall comply with the requirements of ASTM specification D 1248 for type I, Class A, B, or C; category 5; grade E 5 or J 3.
6.2.2.3 Cross-Linked polyethylene (XLPE)
Insulation compound based on chemically cross-linked polyethylene conforming to ASTM specification D 2655. The base polymer of this insulation consists substantially of polyethylene or a polyethylene copolymer.
6.2.2.4 Polyvinylidene fluoride (PVDF)
Insulation compound based on specially chemical-resistant modified polyvinylidene fluoride conforming to ASTM specification D 3144.
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7. SPECIFIC CABLE REQUIREMENTS
7.1 Positive Conductor Cable
7.1.1 Cable for use as a positive conductor shall be single core, stranded soft annealed copper as per subclause 6.1.
7.1.2 Cable insulation, as will be specified by the Purchaser, shall be either standard or chlorine resistant type and shall conform to one of the following alternatives:
7.1.2.1 Standard type cable
7.1.2.1.1 Cable insulation shall be in accordance with one of the following alternatives, as will be specified by the Purchaser (see Appendix A).
- A single jacket of High Molecular Weight Polyethylene (HMWPE), (see 6.2.2.2).
- A double jacket of High Molecular Weight Polyethylene primary insulation / Polyvinylchloride sheath (see 6.2.2.2 and 6.2.2.1).
- A double jacket of Cross-Linked Polyethylene (XLPE) primary insulation/Polyvinylchloride sheath (see 6.2.2.3 and 6.2.2.1).
7.1.2.1.2 The average thickness of cable insulation shall be 2.8 mm for conductor sizes up to 35 sq. mm and 3 mm for larger sizes. The minimum thickness at any point shall not be less than 90% of the specified average thickness. In case of double jacket the thickness of sheath shall not be less than 1.5 mm.
7.1.2.1.3 Unless otherwise specified by the Purchaser, the color of cable insulation shall be fade-resistant red.
7.1.2.2 Chlorine resistant type cable
(To be used as positive cable in saline water and salty soil ground beds).
7.1.2.2.1 Cable insulation shall be in accordance with one of the following alternatives, as will be specified by the Purchaser (see Appendix B).
- A single jacket of Polyvinylidene Fluoride (PVDF), single or double extruded with the minimum thickness of 0.75 mm. (see 6.2.2.4).
- A double jacket of a radiation cross-linked Polyvinylidene Fluoride primary insulation/High Molecular Weight Polyethylene sheath (minimum thickness 0.5 + 1.7 = 2.2 mm).
7.1.2.2.2 Unless otherwise specified by the Purchaser, the color of cable insulation shall be fade-resistant red.
7.2 Negative, Bond or Test Conductor Cable
7.2.1 All cables for use as negative conductor, bond conductor, or test conductor shall be single core, stranded soft annealed copper as per subclause 6.1.
7.2.2 Cable insulation (see Appendices C & D), shall be in accordance with one of the following alternatives:
- A single jacket of High Molecular Weight Polyethylene (HMWPE), (see 6.2.2.2).
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- A single jacket of Cross-Linked polyethylene (XLPE), (see 6.2.2.3).
- A double jacket of polyvinylchloride primary insulation/polyvinylchloride sheath (see 6.2.2.1).
7.2.3 Minimum thickness of cable insulation shall be 1.0 mm for conductor sizes 6.0 sq. mm or less, 1.5 mm for conductor sizes up to 25 sq. mm and 2 mm for larger sizes.
7.2.4 Unless otherwise specified by the Purchaser, the color of cable insulation shall be fade-resistant black.
8. QUALITY ASSURANCE PROVISIONS
It is the responsibility of the manufacturer to establish quality assurance by quality control procedures which shall ensure that the product will meet the requirements of this Part of Standard specification.
The quality control at the manufacturing plant shall include control systems on the following:
- Raw materials, i.e. checking of documentation and/or testing for conformity with the specification.
- Production equipment and process.
- Testing during and after production (see 9).
- Identification of cables.
- Dimension tolerances.
- Documentation (material certificates).
9. TESTS
9.1 Tests shall be carried out to confirm that the materials comply with this Part of Standard specification and all cables shall satisfactorily pass such tests.
9.2 The factory acceptance tests shall be done on test samples taken from the end of each manufactured length (drum) at a temperature of 20°C and shall cover at least the following:
- Dimensions and construction.
- Dielectric strength of insulation.
- Insulation resistance.
- Electrical resistance of conductor.
- Voltage test.
9.3 All tests shall be carried out in accordance with relevant specifications prescribed in subclauses 6.1 and 6.2.
9.4 Unless otherwise specified in this Part of Standard specification, the methods of sampling and testing shall be in accordance with applicable methods of the International Electrotechnical Commission (IEC), British Standards Institution (BSI), and/or Underwriters Laboratories Inc. (UL) latest edition.
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10. INSPECTION
10.1 Responsibility for Inspection
10.1.1 The manufacturer is responsible for the performance of all inspection and tests required by this Part of Standard specification using his own or other reliable facilities and he shall maintain complete records of all such tests and inspections. Such records shall be available for review by the Purchaser.
10.1.2 All tests and inspections shall be made at the place of manufacture. The manufacturer shall afford the inspector representing the Purchaser all reasonable facilities to satisfy him that the material is being furnished in accordance with this Part of Standard specification. Such inspections in no way relieve the manufacturer of his responsibilities under the terms of this Part of Standard specification.
10.1.3 Conformance of the cable to the requirements of this Part of Standard specification shall be determined on samples taken from each lot (see 3) of cable presented for acceptance.
10.1.4 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.
10.1.5 The purchaser’s inspector shall have access to the material subject to inspection for the purpose of witnessing the selection of the samples, the preparation of the test samples, and the performance of the test(s). For such tests, the inspector shall have the right to indicate the pieces from which the samples will be taken in accordance with the provisions of this Part of Standard specification.
10.1.6 If any of the samples found not to conform to this Part of Standard specification materials represented by such sample will be rejected.
10.2 General Examination
A visual inspection for the conformity of cables with the requirements specified in this Part of Standard specification and with a good manufacturing practice shall be carried out on cable pieces.
10.3 Conductor Examination
Compliance with the requirements for conductor construction of IEC Publication 228 or ASTM specification B8 shall be checked by inspection. The cross-sectional area shall be checked by measuring the electrical resistance. No measurements of wire diameters shall be required in checking the conductors.
10.4 Thickness of Insulation and Sheath
The thickness of insulation and sheath (if any) shall be checked on a manufacturing length to ensure minimum insulation thickness. The test method shall be in accordance with ASTM methods of testing D 2633 or D 470 complying with the appropriate requirements of Clause 7.
10.5 Insulation Resistance Test
This test shall be made on a single sample per cable type, in accordance with ASTM methods of testing D 2633 or D 470. For standard type cables test shall be carried out by the submerging the sample in pure water. For chlorine resistant type cables this shall be water with an admixture of salt, 30 grams per liter.
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11. CERTIFICATION
11.1 The manufacturer’s and/or supplier’s certification shall be furnished to the Purchaser stating that samples representing each lot have been manufactured, tested, and inspected in accordance with this Part of Standard specification and the requirements have been met.
11.2 The test reports shall contain results of tests required by this Part of Standard specification and other tests specified by the Purchaser.
11.3 Each test report shall be signed by an authorized agent of the seller and/or manufacturer.
11.4 Certified test reports furnished by the manufacturer shall be properly identified with each lot (batch) of products.
12. PACKAGING AND SHIPMENT
12.1 The cables shall be supplied on non-returnable rigid reels in continuous lengths for the cable size involved, with the inner end of cable brought out through the side of the reel(s).
12.2 The cable shall be placed on the reels so that it will be protected from damage during shipment. Each end of the cable shall be firmly and properly secured to the reel. Care shall be taken to prevent looseness of reeled cable.
12.3 The reels shall be lagged or covered with suitable material to provide physical protection for the cables during transit and during ordinary storage and handling operations.
12.4 The manufacturer shall be solely responsible for the adequancy of the preparation for shipping provisions employed with respect to materials and their application to insure that the cable reaches its destination in perfect working condition when handled by commercial carrier systems.
13. LABELING
13.1 Cable Identification
All insulated or jacketed cable shall be durably marked at intervals not exceeding 60 cm with the following minimum information in addition to any standard requirements.
- The maximum working voltage for which the cable was tested or approved.
- The proper designation for the type of cable (positive, negative, chlorine-resistant) and insulation and sheath.
- The manufacturer’s name, trademark or other distinctive marking from which the cable manufacturer can be readily identified together with year of manufacture.
- The sq. mm size of conductor.
- The standard to which the conductor conforms (see 6.1).
13.2 Marking of Reels
Each reel and each crate or pallet shall be plainly and durably marked with the following information:
Name: Cathodic Protection Cable ..........................................................................................
Specification: IPS-M-TP-750: Part 7 .......................................................................................
Order No.: .........………………………………………………….................................................
M.E.S.C No.: .....…………………………………………………................................................
Type of cable: (i.e. positive, negative, bond or test) ............…...............................................
Type of insulation: (i.e. standard or chlorine-resistant) .........................................................
Length of cable on reel: ..................................................................................................... (m)
No., size (mm) and type of conductor: ..........….......................................................................
Cable configuration: ................................................................................................................
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Thickness (mm) and material of insulation: ............................................................................
Thickness (mm) and material of sheath: ................................................................................
Voltage rating: ....…………………………………………………................................................
Batch No.: .........………………………………………………….................................................
Stock No.: ..........…………………………………………………...............................................
Date of manufacture: ............................................................................................................
Quantity of reel on each crate or pallet: ................................................................................
Name or trademark of the supplier: ......................................................................................
Manufacturer’s name and address: .....................................................................................
14. GUARANTEE
Suppliers of cables under this Part of Standard specification shall certify that such cables meet all requirements of this Standard specification, and is of first-class material and workmanship throughout. Suppliers shall replace any length of cables failing under any of the following conditions.
- Under a voltage test after installation, performed before cable is placed in service but within 18 months from date of shipment.
- During normal and proper use within one year of date of commissioning, the commencement of such year being not more than 12 months from date of shipment.
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APPENDICES
APPENDIX A
DATA SHEET
(TO BE SUBMITTED BY THE PURCHASER)
FOR
IPS-M-TP-750: Part 7 CATHODIC PROTECTION CABLE
Positive cable, standard type, single core, 600/1000 Volts, copper conductor, insulated for use as positive conductor in impressed current cathodic protection systems.
The cable shall be in accordance with the latest edition of above Iranian Petroleum Standard with the following specific requirements:
- Project title: ............................................ - Date: .........................................
- Indent No.: ............................................. - Purchaser:..................................
- M.E.S.C No.: ........................................
- Length of cable required: ...................... meters
- Individual drum length: .........................
- Conductor size: ..................................... mm²
- Type of insulation: b Single jacket- HMWPE
b Double jacket- HMWPE/PVC
b Double jacket- XLPE/HMWPE
- Sheath color: ........................................
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APPENDIX B
DATA SHEET
(TO BE SUBMITTED BY THE PURCHASER)
FOR
IPS-M-TP-750: Part 7 CATHODIC PROTECTION CABLE
Positive cable, chlorine resistant type, single core, 600/1000 Volts, copper conductor, insulated for use as positive conductor in saline water and salty soil ground beds in impressed current cathodic protection systems.
The cable shall be in accordance with the latest edition of above Iranian Petroleum Standard with the following specific requirements:
- Project title: ............................................ - Date: .........................................
- Indent No.: ............................................. - Purchaser:..................................
- M.E.S.C No.: ........................................
- Length of cable required: ...................... meters
- Individual drum length: .........................
- Conductor size: ..................................... mm²
- Type of insulation: b Single jacket PVDF
b Double jacket PVDF/HMWPE
- Sheath color: ........................................
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APPENDIX C
DATA SHEET
(TO BE SUBMITTED BY THE PURCHASER)
FOR
IPS-M-TP-750: Part 7 CATHODIC PROTECTION CABLE
Negative cable, single core, 600/1000 Volts, copper conductor, insulated for use as negative conductor in cathodic protection systems.
The cable shall be in accordance with the latest edition of above Iranian Petroleum Standard with the following specific requirements:
- Project title: ............................................ - Date: .........................................
- Indent No.: ............................................. - Purchaser:..................................
- M.E.S.C No.: ........................................
- Length of cable required: ...................... meters
- Individual drum length: .........................
- Conductor size: ..................................... mm²
- Type of insulation: b Single jacket- HMWPE
b Single jacket - XLPE
b Double jacket PVC/PVC
- Sheath color: ........................................
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APPENDIX D
DATA SHEET
(TO BE SUBMITTED BY THE PURCHASER)
FOR
IPS-M-TP-750: Part 7 CATHODIC PROTECTION CABLE
Cable, single core, 600/1000 Volts, copper conductor, insulated for use as bond conductor or test conductor in cathodic protection systems.
The cable shall be in accordance with the latest edition of above Iranian Petroleum Standard with the following specific requirements:
- Project title: ............................................ - Date: .........................................
- Indent No.: ............................................. - Purchaser:..................................
- M.E.S.C No.: ........................................
- Length of cable required: ...................... meters
- Individual drum length: .........................
- Conductor size: ..................................... mm²
- Type of insulation: b Single jacket - HMWPE
b Double jacket PVC/PVC
- Sheath color: ........................................
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Note:
Typical current ratings are given as a guide only- always check manufacturer’s rating for the particular site operating conditions, including all relevant derating factors.
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PART 8
INSULATING JOINT
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CONTENTS : PAGE No.
1. SCOPE.......................................................................................................................................123
2. REFERENCES...........................................................................................................................123
3. UNITS.........................................................................................................................................124
4. TECHNICAL DOCUMENTS.......................................................................................................124
5. DESIGN......................................................................................................................................125
6. MATERIALS...............................................................................................................................126
7. MANUFACTURE........................................................................................................................127
8. WELDING REQUIREMENTS.....................................................................................................128
9. COATING...................................................................................................................................128
10. QUALITY ASSURANCE PROVISIONS...................................................................................129
11. TESTS......................................................................................................................................129
12. INSPECTION............................................................................................................................131
13. TEST CERTIFICATES..............................................................................................................132
14. PACKING AND SHIPMENT.....................................................................................................132
15. LABELING...............................................................................................................................133
APPENDICES:
APPENDIX A DATA SHEET FOR INSULATING JOINT...............................................................134
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1. SCOPE
This Part of IPS-M-TP-750 covers the minimum requirements for the design, fabrication and inspection of monolithic insulating joints, for electrical isolation of pipelines from plants and/or other pipelines.
Notes:
1) The purpose of insulating joints is to provide electrical isolation between sections of pipelines to prevent detrimental electrochemical interaction between the sections. Insulating joints are used also to ensure effective current distribution for cathodic protection systems.
2) The insulating joint is intended to be installed under/above ground or above water. It is intended to be girth welded between two pipeline sections.
2. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These referenced documents shall, to the extent specified herein, form a part of this standard. For dated references, the edition cited applies. The applicability of changes in dated references that occur after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated references, the latest edition of the referenced documents (including any supplements and amendments) applies.
ANSI (AMERICAN NATIONAL STANDARDS INSTITUTE)
B 16.5 "Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys"
B 31.8 "Gas Transmission and Distribution Piping Systems"
ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)
B 16.25 "Buttwelding Ends"
Boiler and Pressure Vessel Code, Section VIII,
"Rules for Construction of Pressure Vessels", Division 1
Boiler and Pressure Vessel Code, Section IX,
"Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators"
Boiler and Pressure Vessel Code, Section V,
"Non-Destructive Examination"
ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)
A 105 Standard specification for
"Forgings, Carbon Steel for Piping Components"
A 370 Standard test method and definitions for
"Mechanical Testing of Steel Products"
A 694 Standard specification for
"Forgings, Carbon and Alloy Steel, for Pipe Flanges, Fittings, Valves and Parts for High Pressure Transmission Service"
D 709 Standard specification for
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"Laminated Thermosetting Materials"
D 2000 Standard classification system for
"Rubber Products in Automotive Applications"
API (AMERICAN PETROLEUM INSTITUTE)
1104 "Standard for Welding Pipelines and Related Facilities"
5L "Line Pipe"
ISO (INTERNATIONAL ORGANIZATION FOR STANDARDIZATION)
8501-1 "Preparation of Steel Structures Before Application of Paints and Related Products-Visual Assessment of Surface Cleanliness"
10474 "Steel and Steel Products Inspection Documents"
MSS (MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY)
SP-44 "Steel Pipeline Flanges"
SP-75 "Specification for High Wrought Welding Fittings"
BSI (BRITISH STANDARDS INSTITUTION)
BS 5493 Code of practice for
"Protective Coating of Iron and Steel Structures Against Corrosion"
NACE (NATIONAL ASSOCIATION OF CORROSION ENGINEERS)
TM-01-87 "Evaluating Elastomeric Materials in Sour Gas Environments"
MR-01-75 "Material Requirements Sulfide Stress Cracking Resistance-Metallic Materials for Oilfield Equipment"
3. UNITS
This Standard is based on International System of Units (SI), except where otherwise specified.
4. TECHNICAL DOCUMENTS
The technical bid shall include the following:
a) Comprehensive catalogues, technical data, general arrangement drawings showing outline dimensions, proposed test procedure, etc. of the offered insulating joint(s).
b) Detailed drawings showing all parts with material identification and stress/design calculations.
c) Welding procedure specification.
d) Material specifications for the following items:
- Steel forgings
- Insulating rings
- Seal Gaskets
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- Epoxy resin filler material
- External coating
- Internal coating
e) Assembly procedure.
f) Records of tests.
g) Declaration of confirmation with this Part of Standard specification and/or clear indication of deviations from this Standard specification.
h) Specification of packing.
5. DESIGN
5.1 All insulating joints shall be of monolithic type fabricated by welding and with pups on either side. The insulating joints shall be suitable for pigging operations.
5.2 The design of the insulating joint(s) shall be compatible with the design code adopted for the pipeline in which it is installed, as stated in the data sheet.
Note:
ANSI/ASME B 31.4 and B 31.8 are commonly adopted pipeline codes. In some situations, e.g. within plant fences, the pipeline sections connected to the insulating joint may be designed to a plant piping code, e.g. ANSI/ASME B 31.3.
5.3 The insulating joint(s) shall be designed so that it’s bending moment along with projection pressure to be able to generate a longitudinal stress equal to 75% of the adjacent pipe pups.
5.4 The insulating joint(s) shall be designed following the methodology described in ASME VIII Division 1 Appendix 2 or equivalent, using the design pressure, design temperature and design factor of the pipeline, and the anticipated external loads acting on the insulating joint. Stress due to internal design pressure shall not exceed 50% of specified minimum yield strength of material.
5.5 The insulating joint(s) must be assembled so that its internal components are tightly fixed in the required position. To this purpose an assembling precompression, adequately calculated, shall be applied.
5.6 The number of weldings must be as 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 Section VIII Div. 1 ULW 17.6.
5.7 For sour service conditions (when specified), the materials shall comply with the requirements of NACE Standards MR 01 75 and TM 01 87.
5.8 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 fluid’s internal pressure at the same height from the two sides of the rigid insulating ring.
Sealing systems which foresee o-rings cannot be accepted.
The gaskets shall be made of an age resisting elastomer of a high dielectric characteristics. It shall resist explosive decompression, and shall be suitable for long-term exposure to the transported fluid at the design pressure and temperature conditions.
5.9 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.
The insulating material shall be non-hygroscopic and shall be of sustaining high compressive stresses. The material shall have good long-term stability, excellent dielectric strength, and thermic
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properties without cracking, distorting, or a loss of insulating properties. The material shall be flame resistant, and also resistant to hydrocarbons, sulphides, bacteria and the climatic conditions specified in Appendix A.
5.10 The internal diameter of the joint shall not deviate by more than ±2% from the nominal internal diameter of the pipeline.
5.11 Construction shall not incorporate any flanges, boltings, gaskets, and shall be of rigid and rugged design suitable for field installation without a maintenance pit when installed either on a buried or surface laid pipeline.
5.12 Tension and compression shall be axially transmitted satisfactorily and without appreciable elongation or contraction.
The joint shall indicate no unacceptable deformation when under maximum pressure and temperature.
5.13 The manufacturer shall take into consideration that, during the tie-in to the pipeline, the rings of the rigid insulating material, must not exceed a temperature of 70°C.
5.14 The minimum overall lengths for the joints (as measured between ends) of given size and pressure class shall be as follows:
ANSI CLASS RATING

Note:
For pipelines with a wall thickness exceeding 25 mm, the manufacturer/supplier shall confirm that the length of the joint is suitable for post weld heat treatment of the field welds, i.e. the heat generated by the treatment is not detrimental to the isolating and filler materials and the internal coating. If this is not the case, the length of the joint shall be increased accordingly.
6. MATERIALS
6.1 Material for the pressure containing parts of the insulating joints shall meet the requirements of data sheet (see Appendix A).
The metallic parts of the insulating joint shall be of forged1) steel conforming to the requirements of MSS-SP-44.
6.1.1 The ladle analysis of each heat of steel used in the manufacture of insulating joint shall conform to the material degree that is declared to be used with the restrictions foreseen by Para. 6.1.2.
1) Forged, fully killed, normalized or hardened and tempered materials will have to be used according to the schedule here below:
APPROVED STUB MATERIAL FORGED MATERIAL
API 5L Gr. A ASTM A 105
API 5L Gr. B ASTM A 105
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API 5L × 42 ASTM A 694 F 42 or F 52
API 5L × 52 ASTM A 694 F 52
API 5L × 60 ASTM A 694 F 60
API 5L × 65 ASTM A 694 F 65
6.1.2 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
Materials, quality and size of the pups shall be the same as or better than those of the pipe to be connected (see data sheet).
6.2 Insulating materials shall be made of age resisting laminated epoxy resin reinforced with glass fiber conforming to ASTM specification D 709 Type IV Group G 10/G 11 or equivalent standard.
6.3 The primary and secondary sealing gaskets shall be made of fluorinated elastomers like PTFE and/or Butadieneacrylonitrile copolymers like Nitrile rubber according to ASTM specification D 2000, or equivalent standard.
6.4 Filling materials shall be of adhesive sealant elastomer having a compressive strength greater than 1500 kg/cm².
7. MANUFACTURE
7.1 The manufacturer shall be responsible for the integrity of the manufacturing procedures and adherence to this Part of Standard specification.
7.2 The assembly of insulating joint(s) shall be done in a controlled, clean environment.
7.3 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.
7.4 The surface of the annular space between the pup and the retainer shall be abrasive shot-blasted to SA 2½ grade in accordance with ISO 8501-1. Assembly of the insulating joint shall commence within 2 hours after completion of abrasive shot blasting.
7.5 The annular space between the retainer and the pup shall be filled with an epoxy resin filler material; to be approved by the Purchaser’s representative.
7.6 Any depressions in the insulating joint shall be filled with adhesive sealant elastomer to prevent the deposition of sediment at this point.
7.7 Insulating joint(s) shall not be of harmful defect specified on para. 14.5.2 of MSS-SP-75 and the other defects in surface shall be removed according to Para. 14.5.3 of MSS-SP-75.
7.8 All butt welds shall be heat treated after all welding has been completed in accordance with the requirements of ASME Boiler and Pressure Vessel Code, Section VIII.
7.8.1 Lamination found at the bevel end parts shall be removed wholly.
7.8.2 The height of internal weld beads shall be less than 2 mm.
7.8.3 Under-cutting on weld seam shall not be permitted.
7.9 The end connections shall be beveled for welding in accordance with MSS-SP-75, unless otherwise specified by the Purchaser, to allow welding to the pipeline with only two circumferential butt welds. Welding bevels shall be dry and free from grease and other contaminants.
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7.10 For a distance of 100 mm from the welding ends, the internal diameter shall not deviate by more than ±1.5 mm from the nominal internal diameter of the pipeline.
7.11 Heat-treatment for insulating joint(s) shall be performed according to ASME VIII, Division I and related ASME specification.
In this case, the temperature in furnace shall be recorded and controlled continuously during processing, and record chart shall be submitted to purchaser. When required, before manufacturing, supplier shall submit the heat treatment specification described following items:
- Heat-treatment procedure.
- Standard temperature curve chart.
- Temperature control range.
8. WELDING REQUIREMENTS
8.1 Approved Welding Processes
Any of the following processes may be used:
a) Shielded Metal Arc Welding (SMAW).
b) Gas Tungsten-Arc Welding (GTAW or TIG).
c) Gas Metal-Arc Welding (GMAW, or MIG).
d) Submerged Arc Welding (SAW).
e) Combinations of above processes.
8.2 Procedure Qualifications
Welding procedures shall be qualified in accordance with ASME Section IX.
8.3 Welder Qualifications
Welders shall be qualified in accordance with the requirements of ASME Section IX.
8.4 Consumable Materials
Electrodes, filler wires and fluxes shall conform to AWS specifications A 5.1 through A 5.30 as applicable.
8.5 Weld Details
All joints shall be butt-welded and have full penetration welds except for the final closure weld, which shall be welded in accordance with ASME VIII ULW 17.6, Fig. "A".
9. COATING
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 2½ grade in accordance with ISO 8501-1. After visual inspection, all insulating joints shall be externally and internally coated with an 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 supplier’s specification. Beveled ends for 50 mm approx. shall be painted with rust preventive paint.
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Note:
Epoxy internal coatings may not be suitable for some chemical products. When other coatings need to be specified, advice from a material specialist should be taken. Metallic pigmented coatings shall not be used.
The coatings shall be subject to holiday detection using a wet sponge tester set at 60 volts. The acceptance level shall be zero pinholes.
10. QUALITY ASSURANCE PROVISIONS
It is the responsibility of the manufacturer to establish quality assurance by quality control procedures which shall ensure that the product will meet the requirements of this Part of Standard specification.
The quality control at the manufacturing plant shall include control systems on the following:
- Raw materials, i.e. checking of documentation and/or testing for conformity with the specification.
- Production equipment and process.
- Testing during and after fabrication.
- Checking of dimensions.
- Documentation (material certificates).
As alternative to above control system the manufacturer can have quality assurance system in accordance with ISO 9002.
11. TESTS
11.1 General
Tests shall be carried out to conform that the materials comply with this Part of Standard specification and all insulating joints shall satisfactorily pass such tests.
11.2 Items of Test and Inspection
TEST ITEM
MANUFACTURER
PURCHASER
WITNESS
RECORD
Chemical analysis
Mechanical test
Hydraulic test or air tightness test
Radiographic test
Coating inspection
Dielectric test & megger test
Ultrasonic test & magnetic particle test
Dye penetration test
Visual inspection
Dimension check
Heat treatment

Legend:
0 : Operation & record
* : Document check
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11.3 Chemical Analysis
Chemical analysis shall be performed by the ladle analysis for each heat of steel used and shall conform to the requirements of the chemical composition for the respective materials as per relevant standard.
11.4 Mechanical Test
Tensile test is performed for each lot after heat-treatment.
The same charged, shaped and heat-treated products are considered 1 lot.
1) Forgings
The tensile tests shall be performed according to ASTM A 370 code corresponding to equivalent material and the results shall comply with the mechanical requirements in this Part of Standard specification.
2) Pups
The tensile tests shall be performed according to Section 3, Mechanical Properties and Tests of API 5L. No leakage or pressure drops shall be permitted during the test.
11.5 Dielectric Test and Megger Test
Upon completion of the assembly and prior to the hydrostatic test, each insulating joint shall be megger tested with 1000 V. d.c. Minimum resistance shall be 25 Meg ohms.
Each insulating joint shall also be dielectric tested at 5000 V. a.c. (50 Hz) for 1 minute. There shall be no corona effects or breakdown.
The above stated tests shall be repeated after hydrostatic test. The readings before and after the hydrostatic test shall be equal.
11.6 Hydrostatic Test
The insulating joint shall be hydrostatically tested, in an unrestrained condition, using water with a low surface tension, at 1.5 times the rating (permissible working pressure).
In the test, the insulating joint shall be subjected to the full axial load deriving from the hydrostatic pressure unless it has been verified in a type test that the insulating joint is able to resist the full axial load in service.
Unless otherwise specified by the Purchaser the maximum test pressure shall be maintained for at least three hours. No leaks or unacceptable deformation shall occur during the test.
11.7 Low Pressure Leakage Test (Air Test)
After hydrostatic test, a low pressure leakage test shall be carried out on each insulating joint. The joint shall be filled with air and will be pressurized to 0.5 MPa and held at that pressure for 10 minutes. No leakage or pressure drops shall be permitted during the test.
11.8 Prototype Tests
Prototype tests shall be required if the manufacturer can not provide data of similar tests to the satisfaction of the Purchaser.
Prototype joints, representative of production, selected for test shall be identified as to material, grade, and lot, including heat treatment, hydrostatic cyclic pressure tests, hydrostatic pressure plus bending test, and vacuum test where appropriate.
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11.9 Radiographic Test
All butt welds shall be 100% radiographed by X-ray in accordance with Section V of the ASME Boiler and Pressure Vessel Code Non-destructive Examination.
11.10 Magnetic Particle and Ultrasonic Test
11.10.1 The final closure weld shall be inspected by ultrasonic or magnetic particle methods in accordance with ASME Section VIII.
11.10.2 All finished bevel ends shall be 100% ultrasonically tested for lamination type defects for a distance of 50 mm from the ends. Lamination shall not be acceptable.
Notes:
1) The ultrasonic examination method shall be applied before preparing weld edges, especially for areas of 25 mm width around the edge.
2) The magnetic particle examination shall be made only after completion of weld edge preparation.
11.10.3 Acceptance criteria shall be as per ASME Sec. VIII Div. I, Appendix 12.
11.11 Dye Penetrant Test
Dye penetrant test shall be performed on the machined surface according to ASME Section VIII, DIV. I. Appendix 8.
11.12 Visual Inspection and Dimensional Check
11.12.1 Visual inspection of all parts prior to assembly and after finishing of the insulating joint shall be carried out by the manufacturer. General appearance shall show good workmanship.
11.12.2 Dimensions of the insulating joint(s) shall be checked against the specifications, purchase order description and/or approved manufacturer drawings.
11.12.3 The inside and outside thickness of coating shall be checked and it shall not be below the values indicated in Clause 9. The coating appearance shall be even on the whole surface.
12. INSPECTION
12.1 The manufacturer/supplier shall be responsible for carrying out all the tests and inspections required by Part 8 of this Standard specification, using his own or other reliable facilities, and he shall maintain complete records of all such tests and inspections. Such records shall be available for review by the Purchaser. Certified tests and inspection reports shall be properly identified with each batch (lot) of product. The manufacturer shall afford the Purchaser’s inspector all reasonable facilities necessary to satisfy him that the insulating joint(s) are fabricated in accordance with the provisions of this Part of Standard specification.
12.2 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.
12.3 If the Purchaser desires that his representative inspect or witness the inspection and testing of the product prior to shipment, the manufacturer/supplier shall afford the Purchaser’s representative
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all reasonable facilities to satisfy him that the product meets the requirements of this Specification. Such inspections in no way relieve the manufacturer/ supplier of his responsibilities under the term of this Part of Standard specification.
12.4 Purchaser’s inspector(s) shall have free access to the manufacturer’s 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 Purchaser’s 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.
12.5 An inspection certificate shall be provided by the manufacturer in accordance with the following:
• ISO 10474 Type 5.1.B for chemical analysis, mechanical properties, notch toughness properties, hardness properties, heat treatment, non-destructive examination.
• ISO 10474 Type 5.1.C for other tests, e.g. dimensional checks, pressure test (when specified), functional checks.
12.6 The insulating joints may be rejected if measurement, inspection and/or testing reveal discrepancies between quoted figures resulting in purchase order documents (including this Part of Standard specification and its attachments), and those obtained actually.
13. TEST CERTIFICATES
The manufacturer/supplier shall submit following certificates, as a minimum:
a) Test certificates relevant to the chemical and mechanical properties of the materials used for construction as per this Part of Standard specification and relevant standards.
b) Test reports for radiographic and ultrasonic inspection and dye penetration tests.
c) Test certificates for hydrostatic and air tests.
d) Test certificate for electrical tests.
e) Stress relieve and heat treatment certificates.
f) Test certificate for dimensions and sectional drawings.
In addition to the certified material test reports the manufacturer/supplier shall provide a user manual detailing the requirements for installation and inspection in service.
The certificates shall be considered valid only when signed by Purchaser’s inspector.
14. PACKING AND SHIPMENT
14.1 Both ends of each insulating joint shall be closed with slip-on recessed end caps to protect the internal parts and also the beveled ends from any possible damage. Care shall be taken to prevent damage to the external and internal coatings.
14.2 Insulating joints shall be suitably packed and protected against all damages or defects which may occur during transit (sea shipment to the port and rough road haulage to site), and extended tropical open air storage up to 24 months.
Note:
Tack welding of protectors to the joints is not permitted.
14.3 Only those insulating joints which have been inspected and certified by Purchaser’s inspector shall be shipped.
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15. LABELING
15.1 Marking of Insulating Joints
All insulating joints furnished under this Part of Standard specification shall be clearly identified with the information marked with low stress die stamps or interrupted dot stamps on the outside of each completed insulating joint as follows:
a) Manufacturer’s name;
b) joint serial No.;
c) size (DN);
d) thickness of ends;
e) material grade;
f) ANSI rating;
g) maximum working temperature rating, in °C;
h) the year of manufacturing;
i) tag No.;
j) weight.
Note:
When sour service conditions are specified, the insulating joint shall be stamped "NACE MR 0175".
15.2 Marking of Container
Each container of insulating joint(s) shall be marked with the following information:
- Name: Insulating joint........................................................................................................
- Specification: IPS-M-TP-750: Part 8.................................................................................
- Order No.: .......……………………………………………….................................................
- M.E.S.C No.: ....……………………………………………...................................................
- Joint serial No.: ……………………………………………….................................................
- Size (DN): .......……………………………………………….................................................
- Thickness of ends: .........................................................................................................
- Material grade: .……………………………………………..................................................
- ANSI rating: .....……………………………………………...................................................
- Weight:............………………………………………………..................................................
- Temperature rating, in °C: ................................................................................................
- Batch No.: .......……………………………………………….................................................
- Stock No.: .......……………………………………………….................................................
- Date of manufacture: ......................................................................................................
- Quantity: .........……………………………………………...................................................
- Trademark of the manufacturer:......................................................................................
- Manufacturer’s name and address:................................................................................
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APPENDICES
APPENDIX A
DATA SHEET
(TO BE SUBMITTED BY THE PURCHASER)
FOR
INSULATING JOINT
Project title:
Indent No.:
Date:
Quantity:
Purchaser:
b Oil industry
b Gas industry
b Petrochemical industry
ITEM
SELECTION
Pipeline design code
b ANSI B 31.4 b ANSI B 31.8
b Other:
Pipeline design factor
Pipeline outside diameter
mm
Pipeline wall thickness
mm
Pipeline material
Specification: Type/grade:
Pipeline design pressure
bar (ga)
Pipeline design temperature
Minimum: °C
Maximum: °C
Transported fluid
Insulating joint length
mm
Sour services
b Yes b No
Toxic services
b Yes b No
Installation
b Buried b Overground
b Offshore
ADDITIONAL DATA
Made by: Date:
Checked by: Date:
Approved by: Date:
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135
PART 9
FLANGE INSULATION KIT
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CONTENTS : PAGE No.
1. SCOPE.......................................................................................................................................137
2. REFERENCES...........................................................................................................................137
3. DEFINITIONS AND TERMINOLOGY.........................................................................................137
4. UNITS.........................................................................................................................................137
5. TECHNICAL DOCUMENTS.......................................................................................................137
6. GENERAL DESCRIPTION.........................................................................................................138
7. MATERIALS...............................................................................................................................138
8. REQUIREMENTS.......................................................................................................................139
9. PACKAGING..............................................................................................................................141
10. QUALITY ASSURANCE PROVISIONS...................................................................................141
11. SAMPLING...............................................................................................................................142
12. INSPECTION AND TESTING...................................................................................................142
13. LABELING...............................................................................................................................143
APPENDICES:
APPENDIX A DATA SHEET FOR FLANGE INSULATION KIT....................................................144
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137
1. SCOPE
This Part of IPS-M-TP-750 covers the minimum requirements for flange insulation kit, complete, intended for electrical insulation of standard, flat face, raised face, or ring joint type, flanges used for cathodically protected steel pipes and forming part of corrosion protection of the structure.
Appendix A is the data sheet which shall be used for ordering Purposes.
2. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These referenced documents shall, to the extent specified herein, form a part of this standard. For dated references, the edition cited applies. The applicability of changes in dated references that occur after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated references, the latest edition of the referenced documents (including any supplements and amendments) applies.
ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)
B 16.5 "Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and Other Special Alloys"
B 16.20 "Ring-Joint Gaskets and Grooves for Steel Pipe Flanges"
B 16.21 "Non-Metallic Flat Gaskets for Pipe Flanges"
ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)
D 709 Standard Specification for "Laminated Thermosetting Materials"
D 229 Standard Methods of Testing
"Rigid Sheet and Plate Materials Used for Electrical Insulation"
D 883 "Standard Definitions of Terms Relating to Plastics"
F 118 "Standard Definitions of Terms Relating to Gaskets"
D 4088 Standard Practice for
"Preparation for Shipment of Solid Electrical Insulating Materials"
US MILITARY SPECIFICATION
MIL-P-15035 "Plastic Sheet; Laminated, Thermosetting, Cotton-Fabric-Base, Phenolic-Resin"
3. DEFINITIONS AND TERMINOLOGY
For definitions of technical terms pertaining to gaskets and plastics used in this Part of Standard specification see ASTM D 883 and F 118.
4. UNITS
This Standard is based on International System of Units (SI), except where otherwise specified.
5. TECHNICAL DOCUMENTS
The technical bid shall include the following:
a) Manufacturing specification and procedure.
b) Catalogue showing materials, dimensions, and configuration.
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c) Material specification for the components to be offered.
d) Test specification and procedure.
e) Specification of packing.
6. GENERAL DESCRIPTION
6.1 Each kit shall include the following components:
a) Insulating central gasket
b) Insulating bolt sleeves
c) Insulating bolt washers
d) Steel bolt washers
Note:
The insulating sleeve and washer may be supplied as one-piece.
6.2 Gaskets shall be manufactured from material having low water absorption and high compressive strength. Preference shall be given to materials with low y and m factors. The y factor is a measure of the compressive load required to establish an initial seal, while the m factor is an indication of the additional load required to hold the fluid pressure needed to keep the seal in operation. The smaller these factors are, the less bolt loading is required.
Gasket materials shall withstand the expected bolt loading without injurious crushing, and which are suitable for the service conditions. It shall not crack or distort under load and shall be unaffected by salt water, hydrocarbons, natural gas, sunlight or atmospheric conditions.
Note:
The m and y factors for various materials are included in the ASME Code, Section VIII and ASME B 16.5.
6.3 Insulating bolt sleeves shall be manufactured from materials having low water absorption, high dielectric strength, and low cold-flow characteristics. They shall be suitable for the service conditions of the particular application.
6.4 Insulating washers shall be manufactured from materials having high compressive strength, low water absorption, high dielectric strength, and low cold-flow characteristics.
7. MATERIALS
7.1 The central gasket for flat face or raised face flanges shall be made of a fabric-reinforced phenolic laminate core material 1) coated on both sides with a chloroprene polymer (i.e. neoprene) sheets.
7.2 The central gasket for ring joint flanges shall be made from fabric-reinforced phenolic laminate core material 1).
7.3 Insulating sleeves shall be fabricated from high density polyethylene material, to which shall be added only those antioxidants, UV stabilizers and pigments necessary for the manufacture of sleeves to the specification and to its end use.
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1) The fabric-reinforced phenolic laminated core material shall consist of a suitable cotton fabric base or filler properly impregnated and bonded with a phenolic thermosetting resin compound or binder, processed to meet the requirements of this Part of Standard specification, which meet US Military Specification MIL-P-15035 Type F.B.G or ASTM D 709 Type II Grade CE.
Notes:
1) The choice of stabilizers and other additives is at the discretion of the manufacturer.
2) Moulding compounds of unknown composition shall not be used. Impurities which are occasionally contained in polymers shall not exceed 0.1% by mass.
7.4 Insulating washers, except when cast integrally with sleeves, shall be fabricated from fabric-reinforced phenolic material and shall be 3.2 mm thickness (nominal).
7.5 Combined insulating sleeve/insulating washer shall be fabricated from injection molded acetal copolymer or equivalent in the form of a one-piece casting.
7.6 Steel washers shall be fabricated from plated mild steel as per BS-3410 (Table 7), 3.2 mm thickness, and shall be treated to prevent corrosion.
8. REQUIREMENTS
8.1 Dimensions
8.1.1 Unless otherwise specified by the Purchaser, gaskets for flat face or raised face flanges shall conform to the dimensions specified in ANSI B 16.21. They shall have a nominal thickness of 3.2 mm and protrude into the bore of the pipe by 1.5 mm to prevent electrically conductive bridging over the insulation by debris, etc.
8.1.2 Ring gaskets for ring-joint flanges shall be of dimensions established in ANSI B 16.20. Sheet and ring joint gaskets for sizes NPS 10 and smaller shall conform to ANSI B 16.5 dimensions and recommendations.
8.1.3 Insulating bolt sleeves are normally designed for standard bolting in standard bolt holes and shall be of sufficient length to extend halfway inside the steel washer. Care shall be taken to ensure that the dimensions selected will allow the use of the standard size bolt or one size smaller high tensile strength bolt.
8.1.4 Insulating bolt washers shall be sized internally so that the bolt sleeve will pass through, and the OD shall be sized so that the washer will fit inside the flange spot facing.
8.1.5 Steel washers shall be the same size as the insulating washer.
8.2 Uniformity
The materials shall be uniform in texture, finish, and specified properties.
8.3 Surface Defects
The materials shall be free from blisters, wrinkles, air marks, or cracks, and reasonably free from other small defects such as scratches, dents, heat marks, etc.
8.4 Workmanship
All materials and workmanship shall be in accordance with good commercial practice, and the
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