Pipeline Earthing Isolation Accessories

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4

PIPELINE, EARTHING AND ISOLATION ACCESSORIES

4.0 CONTENTS 4.1 Pipeline Isolation 4.1.1 Insulating Flange Kits 4.1.2 Isolation Joints

4.2 Surge Protection / AC Mitigation 4.2.1 Spark Gaps SG4 Type 4.2.2 Spark Gaps Buried Type 4.2.3 Rustrol Cathodic Isolators 4.2.4 Rustrol Solid State Surge Protectors 4.2.5 Zinc Earthing Cells

4.3 Pipe Connection Accessories 4.3.1 Pin Brazing 4.3.2 Thermit Welding Equipment 4.3.3 Handy Caps 4.3.4 Cable Lugs

4.4 Pipeline Accessories 4.4.1 Pipeline Pipeline - Casing Insulators 4.4.2 Link Seals

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.1.1

INSULATING FLANGE KITS REVISION 1  APPLICATION Flange insulation kits for metallic pipelines are available for all flange sizes, types, pressure ratings and materials. Flange insulation kits are commonly installed at each end of a pipeline to electrically isolate the pipe for other buried foreign metallic structures and plant grounding systems therefore limiting the amount of cathodic protection current required  to protect the pipeline.

FLANGE INSULATION KIT DATA 

TYPE "E" GASKETS Have the same outside diameter as the flanges, and are made with precision-located bolt holes. They are easy to centre and will prevent foreign material from becoming lodged between  the flange faces and "shorting out" the flange insulation. Type "E" gaskets are available in a wide variety of materials.

TYPE "F" GASKETS Are made to fit within the bolt hole circle of the flange faces. The outside diameter of the gasket is slightly larger than the inside diameter of the bolt hole circle. They are available in a wide variety of materials.

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: cpc@cathodi [email protected] c.co.uk Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.1.1

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.1.1

INSULATING FLANGE KITS REVISION 1 TYPE "D" GASKETS Are made specifically to fit into the ring groove of RTJ flanges. They are available in reinforced phenolic and other materials.

INSULATING SLEEVES AND WASHERS Are available in complete kits, with or without a gasket. Sleeves and washer are available as separate parts or as a one-piece moulded unit. Sleeves and washers are enclosed in a strong polyethylene bag to eliminate any possibility of loss.

TYPICAL SPECIFICATIONS Standard Specification Range Flange Isolation Kit Specification : Materials for flange isolation kits on pipes containing water, aqueous fluids or natural gas (up to 221ºF, 105ºC) shall consist of the following components: Isolating and Sealing Gasket : One full faced isolating and sealing gasket, LineBacker Type “E”, 1/8” thick, phenolic retainer containing a precision tapered groove to accommodate the controlled compression of a nitrile quad-ring sealing element. Sealing element placement shall accommodate either flat, raised or RTJ face flanges. The quad-ring seal shall be pressure energized. The phenolic retainer shall have a 500 volts/mil dielectric strength and a minimum 25,000 psi compressive strength. The full faced flange isolating gasket shall be 1/8” less in I.D. than the I.D. of the flange in which it is installed. Full Length Bolt Isolating Sleeves : One full length Mylar sleeve (extending half way into both steel washers) for each flange bolt. The Mylar shall be a 1/32” thick tube with a 4000 volts/mil dielectric strength and water absorption of 0.8% or less. Washers : Two, 1/8“ thick, glass clad phenolic isolating washers for each bolt. Their compressive strength shall be 33,000 psi, dielectric strength 500 volts/mil and water absorption 1.6% or less. Two, 1/8” thick steel washers for each bolt. The I.D. of all washers shall fit over the isolating sleeve and both the steel and isolating washers shall have  the same I.D. and O.D.

DATASHEET 4.1.1

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: cpc@cathodic [email protected] .co.uk Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.1.1

INSULATING FLANGE KITS REVISION 1 High Temperature Specification Range Flange Isolation Kit Specification : Materials for flange isolation kits on pipes containing natural gas, oil and aqueous fluids (up to 280ºF, 138ºC) shall consist of the following components: Isolating and Sealing Gasket : One full faced isolating and sealing gasket, LineBacker Type “E”, 1/8” thick, G-10 retainer containing a precision tapered groove to accommodate the controlled compression of a Teflon (or Viton) quad-ring sealing element. Sealing element placement shall accommodate either flat, raised face or RTJ flanges. The quad-ring seal shall be pressure energized. The G-10 retainer shall have a 550 volts/mil dielectric strength and a minimum 50,000 psi compressive strength. The full faced flange isolating gasket shall be 1/8” less in I.D. than the I.D. of the flange in which it is installed. Full Length Bolt Isolating Sleeves : One full length G-10 sleeve (extending half way into both steel washers) for each flange bolt. The G-10 shall be a 1/32 inch thick tube with a 400 volts/mil dielectric strength and water absorption of 0.10% or less. Washers : Two, 1/8” thick, G-10 isolating washers for each bolt. Their compressive strength shall be 50,000 psi, dielectric strength 550 volts/mil and water absorption 0.10% or less. Two, 1/8” thick zinc plated, hot rolled steel washers for each bolt. The I.D. of all washers shall fit over the isolating sleeve and both the steel and isolating washers shall have a same I.D. and O.D. Common LineBacker & Gasket Seal Laminates/Retainers Physical Properties & Max Temperature Limits

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: cpc@cathodi [email protected] c.co.uk Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.1.1

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.1.1

INSULATING FLANGE KITS REVISION 1

ASTM

Test Method

Plain Phenolic

Neoprene Faced Phenolic

G-3 Hi-Temp (*)G-7 (*) G-7 G-10 G-11 Phenolic Silicon Glass Epoxy Glass Epoxy Glass

D149

Dielectric Strength

500

500

550

350-400

550

550

 Volts/Mil  Volts /Mil (short time) D695

Compressive Strength (psi)

25,000

25,000

50,000

40,000

50,000

50,000+

D229

Water Absorbtion (%)

1.60

1.60

0.70

0.07

0.10

0.10

D257

Insulation Resistance (M Ω)

40,000

40,000

46,000

2,500

200,000

200,000

D790

Flexural Strength (psi)

22,500

22,500

60,000

27,000

60,000

75,000+

D785

Hardness Rockwell “M”

85

85

115

105

115

115

D256

IZOD Impact Strength

1.2

1.2

12.0

8.0

14.0

12.0

(ft-lbs/inch) D638

Tensile Strength (psi)

20,000

20,000

42,000

25,000

45,000

43,000

D732

Shear Strength (psi)

10,000

10,000

18,000

20,000

22,000

22,000

Temperature Te mperature Range (ºF )

-65 to

-65 to

-65 to

Cryogenic

Cryogenic

Cryogenic

+220

+175

+392

 to +450

 to +280

 to +350

-54 to

-54 to

-54 to

Cryogenic

Cryogenic

Cryogenic

+104

+79

+200

 to +232

 to +138

 to +177

Temperature Range (ºC)

(*) G-7 Material should not be used with Hydrocarbons, not even in trace amounts

For every enquiry or Order please quote: • Flange Pressure Class and Standard (ANSI, BS, DIN) • Nominal Pipe Diameter • Type E, F or D Flange Kit  • Type of Insulating Material required for Central Gasket & Sleeves • Type of Product being carried by Pipeline

DATASHEET 4.1.1

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: cpc@cathodic [email protected] .co.uk Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.1.2

PIPELINE ISOLA ISOLATION TION JOINTS REVISION 1  APPLICATION In addition to flange insulation kits Cathodic Protection Co Ltd supply boltless factory assembled and tested monolithic flange insulation joints, which can be delivered direct to site ready for welding into the main pipeline. Monolithic insulating  joints are used for the sectioning of main pipelines and service pipelines to ensure adequate Cathodic protection and electrical safety.

PIPELINE ISOLATION JOINTS DATA 

Size Range :

0.5 to 100 inch and over

Rating Class :

ANSI 150 To ANSI 2500 and over.

Elec El ectr tric ical al Tes ests ts (i (in n dry dry air air at 25 De Deg g C) C) :

Diel Di elec ectr tric ic str stren engt gth h test test 30 3000 00V V at at 50H 50Hzz AC fo forr 1 Mi Minu nute te Electrical resistance test > 5 MOhm at 1000V DC

Characteristics :

Max operating pressure equal to the Nominal Pressure (PN/ANSI rating) Test pressure 1.5 times the design pressure Operating temp - 10 to + 70 ºC for normal temps, -10 to + 160 ºC for high temps Carbon Steel Stratified epoxy resin and glass fibre Class G10-G11 Sealing O-rings & Epoxy resin fill Epoxy resin internal/external coating 70 micron DFT

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.1.2

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.1.2

PIPELINE ISOLA ISOLATION TION JOINTS REVISION 1 TYPES AND DIMENSIONS AVAILABLE (OVER PN 10 RATING)

• Dimensions in mm • Alternative wall thickness on request 

INSPECTION AND TEST Hydro-pneumatic te test

NDE ex examination

Helium test

Holiday and adhesion test  

Thermal shock test 

DATASHEET 4.1.2

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.1

SPARK GAPS SG4 TYPE REVISION 1  APPLICATION Lightning protection equipotential bonding in hazardous areas. In accordance with DIN VDE 0185

SPARK GAP DATA 

Type

E xF S

Installation

At insulating flanges or at isolating joints

 Versions

Type

Cable Length

For Flange dims

Pt No

ExSF L300

300mm

220 – 320mm

923 062

Connection bracket

Type IF 1, Pt No 923 011, ma maxximu mum m hole diameter to suit flange bolt is 60mm (indicate hole diameter with order)

Enclosure

Die cast zinc/plastic

Connection

M10 screw or connection cable 1x25mm2 with cable lug & M10 screw/nut  

Dimensions

63mm dia x 90mm long

TECHNICAL DATA  Nominal discharge current (8/20) isn

100kA

Lightning impulse current Iimp

corresponding to DIN 48810

AC sparkover voltage (50Hz) U aw

1kV 

100% standard lightning sparkover voltage (1.2/50) Uas100

2.2 kV  

Degre Deg ree e of prote protecti ction/ on/app approv roval al

Speciall degree Specia degree of of protec protectio tion n (Ex)s (Ex)s accord according ing to to DIN VDE VDE 0171, 0171, §49, temp class G4 (PTB Cert No : III B/E – 23 805)

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.2.1

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.2

SPARK GAPS BURIED TYPE REVISION 1  APPLICATION Lightning protection equipotential bonding in hazardous areas In accordance with DIN VDE 0185

Type

Ex-FS KU

Installation

Adjacent to buried isolating joints

Cable

2 x 1500mm lengths factory assembled

TECHNICAL DATA  Nominal discharge current (8/20) isn

100kA

Lightning impulse current Iimp

corresponding to DIN 48810

AC sparkover voltage (50Hz) U aw

1kV 

100% standard lightning sparkover voltage (1.2/50) Uas100

2.2 kV 

Degre Deg ree e of prote protecti ction/ on/app approv roval al

Speciall degree Specia degree of of protec protectio tion n (Ex)s (Ex)s accord according ing to to DIN VDE VDE 0171, 0171, §49, temp class G4 (PTB Cert No : III B/E – 23 805)

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.2.2

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.3

CATHODIC ISOLATORS REVISION 1  APPLICATION Onshore – Pipelines & Storage Tanks

CATHODIC ISOLATOR DATA  Electrical Isolation for Effective Cathodic Protection

The uniquely designed Cathodic Isolator ™ developed by  Rustrol® Systems effectively confines the current needed for cathodic protection, while providing a safe grounding path during all types of electrical disturbances.

Cathodic protection, proven by decades of service in a  variety of applications, prevents corrosion of buried or submerged metallic structures. Cathodic protection is most efficiently and uniformly applied when the primary structure is electrically isolated isolated – i.e. all metallic/electrical contacts with foreign structures are eliminated. Electrical isolation gives three main benefits: • Restriction of the required protective current to the surface of the primary structure to produce a uniform polarised level of protection. • Minimi Minimizatio zation n of stray DC current current interference interference.. • Prevention of galvanic current between metallic metallic structures. structures.

Safe Cathodic Isolation Cathodic isolation is a superior form of electrical isolation. Cathodic isolation maintains stringent electrical grounding requirements and confines the protective current at the surface of the primary structure. The result is highly  effective, uniform protection against corrosion. The Rustrol® Cathodic Isolator™ meets safety standards for effective grounding and conforms to the need for safe operating practices worldwide, ie; not to exceed 15Volts rms (caution) potential most often stipulated by design. The Cathodic Isolator ™ provides all of the advantages of electrical isolation necessary for cathodic protection by  blocking the protective current at the electrical isolating device – such as across a pipeline isolating flange. As soon as the potential across the isolating flange exceeds the pre-set voltage threshold, the Rustrol ® Cathodic Isolator™ responds instantly.

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.2.3

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.3

CATHODIC ISOLATORS REVISION 1   Versatile Protection The Cathodic Isolator ™ protects personnel and equipment  during all types of electrical disturbances by providing an effective grounding path which instantly conducts: • • • •

AC Fault Currents Lightning AC Induction Power Switching Surge Currents

The Cathodic Isolator ™ is indispensable for safe electrical isolation – to assure unprecedented protection of your personnel and equipment.

Rustrol®’s Proven Quality Assures Reliable Operation

Unique developments in electronic circuitry are incorporated in the Rustrol ® solid state Cathodic Isolator ™  to assure acute sensitivity,, instant response and fail-safe, maintenance free sensitivity operation in a non-electrolytic environment. The Cathodic Isolator™ and associated hardware feature  the most advanced and reliable components now available. Each critical component is precisely machined and carefully  assembled to meet Rustrol ®’s exceptionally stringent quality  assurance standards. Research and development models have undergone  thorough acceptance testing by independent high-current   test facilities and have been fully approved (test data available on request).

Applications for Cost Effective Operation Along with performing a key role in safe and effective corrosion control, the Rustrol ® Cathodic Isolator™ also serves  to reduce both capital and maintenance costs of cathodic protection systems. Cost effective applications include: • AC fault current protection across isolating flanges and other devices. • Mitigation of induced AC on pipelines and other structures. • Lightning protection for equipment, including CP rectifiers. • De-coupling of the primary structure eg; Fuelling facility  from contact with the electrical utilities grounding network.

DATASHEET 4.2.3

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.3

CATHODIC ISOLATORS REVISION 1

DATASHEET 4.2.3

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.4

POLARISATION CELLS REVISION 1  APPLICATION Onshore – Pipelines & Storage Tanks Rustrol® Systems are designed to protect personnel and equipment from electrical disturbances. Rustrol ® Systems effectively block cathodic protection DC voltages; all other electrical disturbances are freely conducted to ground, such as: • AC Fault Currents • Mitigation of induced AC Voltages • Lightning

Rustrol® Polarization Cell Systems Data The Rustrol® Polarization Cell Systems are rated for up to 100 kA AC fault  current capacities, in 5 kA increments. Each Cell System is capable of blocking 1.7 volts DC. A full product line is available to meet the challenge of all applications. Rustrol® Polarization Cell Systems are typically specified for earthing applications where major power disturbances are not the primary  exposure. Some examples include: decoupling a structure from ground rods, casings or other isolated earths. AC power pulses, lightning surges, stray DC interference and induced AC voltages are all standard applications for the Rustrol ® Polarization Cell. All Cells are rated to safely pass _ second (30 cycle) AC fault current, with a terminal potential rise across the Cell, not exceeding 15 volts rms at 20°C. Rustrol® Polarization Cells optimize the safety of personnel and equipment. Rustrol® Polarization Cell Systems are utilized to decouple massive metallic structures where electrical disturbances, caused by AC fault currents, present high-risk exposure. Typically, Typically, Rustrol ® Polarization Cell Systems are specified for direct connections across isolation flange assemblies; between pipe-type cable systems and station ground; or between cathodically  protected structures and the electrical grounding system neutral.

How Rustrol® Cells Work Rustrol® Polarization Cells contain pairs of pure nickel plates immersed in KOH electrolyte. The surfaces of these plates instantly polarize when separated metallic structures are connected to opposite terminals. The polarizing film blocks DC, to contain cathodic protection current, while freely passing AC. Personnel are safely protected from shock hazards during AC faults. Insulating fittings and equipment are protected during electrical disturbances. Separated underground or submerged metallic structures are efficiently  protected. Isolated structures, which must remain effectively grounded to  the AC utility network, are designed to meet this requirement in national electrical safety codes. Installations specifying Rustrol ® Polarization Cells for cathodic isolation, are regularly accepted by North American electrical inspectors.

Quality With A Proven Track Record • Rust Rustro roll® Polarization Cells and hardware are manufactured using only  pure metals as electrical conductors. Components machined and assembled match Rustrol's ® high quality assurance standards. • Researched and developed developed models are fully acceptance-tested to the approval of independent high current test laboratories, prior to marketing. • Worldwi Worldwide de users users of Rustrol Rustrol ® Polarization Cells report that maintenance is minimal when operating at their operating temperature and rated exposure conditions. • Service life of more then then 25 years with minimal variance in the level of  the electrolyte is reported.

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: cpc@cathodi [email protected] c.co.uk Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.2.4

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.4

POLARISATION CELLS REVISION 1

DATASHEET 4.2.4

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: cpc@cathodic [email protected] .co.uk Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.5

ZINC EARTHING CELLS REVISION 1  APPLICATION These products are used for 2 main purposes :1. Instead of a copper grounding rod to avoid bi-metallic corrosion of associated ferrous structures. 2. To mitigate voltages induced onto the pipelines from overhead AC power lines. The pipeline can be grounded using  these electrodes without disruption to the Cathodic Protection current.

ZINC EARTHING ELECTRODE (DOUBLE) DATA  Size Bare

2 No 35 x 35 x 1525mm c/w 12mm Dia M.S. Core Extending 25mm At One End

Size Packaged

165mm Dia x 1700mm Length

Cable

1 x 25mm2 XLPE/PVC (Black) x 5m Length (Or To Client Specification)

Weight

70Kgs (154lbs)

ZINC EARTHING ELECTRODE (SINGLE) DATA  This product combines two zinc reference cells, insulated from one another. One electrode would typically be connected  to the protected structure, the other to an earthing device. The electrodes are surrounded by low resistivity backfill allowing large stray currents to pass between them. The enables the structure to be earthed to ground with providing a direct connection. Size Bare

1 No 35 x 35 x 1525mm c/w 12mm Dia M.S. Core Extending 25mm At One End

Size Packaged

120mm Dia x 1700mm Length

Cable

1 x 25mm2 XLPE/PVC (Black) x 5m Length (Or To Client Specification)

Weight

35Kgs (77lbs)

Zinc Composition Cu : Al : Fe : Cd : Pb : Others : Zn :

0.005% max 0.10 – 0.50% 0.005% max 0.025 – 0.07% 0.006% max 0.10% total Remainder

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.2.5

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.2.5

ZING EARTHING CELLS REVISION 1 ZINC EARTHING ELECTRODE DRAWINGS SINGLE ELECTRODE

DOUBLE ELECTRODE

CABLE CONNECTION

DATASHEET 4.2.5

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.1

PIN BRAZING REVISION 1  APPLICATION Pin Brazing is a safe, reliable and high quality method of making cable attachments to pipelines, tanks or other metallic structures. Typical applications include pipeline bonding, anode cable and negative cable connections and  junction box mounting.

EASYBOND PIN BRAZING EQUIPMENT

The Easybond unit is suitable for all types of installation and maintenance work. The EBM2 unit retains the same reliability as the original Easybond unit with a capacity of 30 brazes on a single battery charge, with electro-mechanical functionality housed in a sturdy, heavy duty enclosure. Features include a charge/braze indicator which tell the operator when to recharge, quick change batteries held in a robust bag with loading strap, and an independent battery charging pack so operators can braze and charge at the same time with an extra battery pack to hand. Complete unit comprises Battery Unit, 3 x Batteries, Brazing Gun, Battery Charger, Earth Device, Carry Case, Manual & Instructions

SAFETRACK S30 XC PIN BRAZING EQUIPMENT S30 X/C is a small hand portable pinbrazing unit made especially for maintenance work on railways and for cathodic protection installations. As with other Safetrack pinbrazing units the S30 X/C an electronically steered, patented Constant Energy output. The power (36V DC) comes from sealed High Power batteries placed in a separate battery box for easy exchanging. S30 X/C can be fitted with a rail  trolley, Handy SAFE 9361. Brazing pins without fuse wire are used. The patented Automatic S4 gun is standard. Features of the unit include • Automatic brazing gun, S4 - No adjustment needed. • Use of brazing pins without fuse wire. • No "waste" of brazing pins • Low maintenance required

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.3.1

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.1

PIN BRAZING REVISION 1 PIN BRAZING CONSUMABLES There are two basic types of connection that can be made • Threaded Type Connection using an M8, M10 or M12 Threaded Brazing Pin. A normal copper crimp lug (supplied separately) is attached to the stud and secured in place with locknuts and washers (included with pin). • Direct Type Connection using an 8mm Direct Brazing Pin and a Pin Brazing cable lug, available to suit cable sizes 10mm2 to 50mm2 For each type of connection a ceramic ferrule is required for each braze in either 12mm (threaded connection) or 8mm (direct connection) size

PACK SIZES Direct Brazing Pin 8mm :

100 No

Threaded Brazing Pin M12 : 40 No

Threaded Brazing Pin M8 :

50 No

8mm Ceramic Ferrule :

200 No

Threaded Brazing Pin M10 :

40 No

12mm Ceramic Ferrule :

100 No

DATASHEET 4.3.1

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.2

THERMITE WELD EQUIPMENT REVISION 1  APPLICATION Onshore, Marine and Concrete Structures

THERMITE WELD DATA  Thermite welding is a simple, inexpensive and efficient method of attaching a copper conductor cable to steel or cast iron. It is particularly useful for connecting cathodic protection cables to pipelines including test leads, negative and bonding cables. The welding process uses a high temperature reaction charge of powdered copper oxide and aluminium which when ignited produces aluminium oxide and super heated copper.

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.3.2

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.2

THERMITE WELD EQUIPMENT REVISION 1

DATASHEET 4.3.2

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.2

THERMITE WELD EQUIPMENT REVISION 1

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.3.2

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.2

THERMITE WELD EQUIPMENT REVISION 1

DATASHEET 4.3.2

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.2

THERMITE WELD EQUIPMENT REVISION 1

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.3.2

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.2

THERMITE WELD EQUIPMENT REVISION 1

DATASHEET 4.3.2

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.3

HANDY CAPS REVISION 1  APPLICATION Coating repair for Pin Brazed or Themit Weld cable connections on pipelines

Exothermic Weld Grounding Connection • No Liquid Primer Needed • Easy Field-Applied Corrosion Protection • Ideal for Keyhole Applications • Dome and Tunnel Provide Easy Access • Tapecoat Gray Adhesive Eliminates Liquid Primer • Elastomeric Compound Encases Weld Profile • Serrations Conform to Small Diameters Handy Cap IP is a prefabricated assembly designed to provide quick, field-applied corrosion protection to anode and test  lead wire welds on metal pipe and tanks. This economical product is ideal for use in limited access applications. New Handy Cap IP now adds the innovative technology of Tapecoat Gray Adhesive to its unique design. The integration of a primer in Tapecoat Gray makes field application of Handy Cap IP easier and more economical. Tapecoat Gray Adhesive bonds the tough outer shell of the Handy Cap IP to the bare metal weld area and surrounding plant applied coating. Innovative Tapecoat Gray incorporates an integrated primer in its adhesive and provides exceptional bonding without the costly application of liquid primer. A protective compound within the dome molds itself over the irregular welded profile and encases the exothermic connection.

TECHNICAL SPECIFICATIONS Application Information: 1. Clean all mud, dirt, grease, oil and other contaminants from the metal surface and mill coating which is to be covered. The Handy Cap IP incorporates an integrated primer in its Tapecoat Gray Adhesive and does not require the use of a liquid primer prior to application. 2. Remove the release paper from the bottom of the Handy Cap IP. IP. Bend the plastic sheet inward at the serrations when applying to small diameter pipe. Position and place the Handy Cap IP on the welded area with the tunnel over  the lead wire. 3. Push the dome of the cap firmly into the weld area. Lift the lead wire away from the pipe and squeeze the adhesive compound completely around and underneath the wire. Push the lead wire back down on the pipe and press the elastomeric compound into firm contact with the pipe over the entire area. No further protection is required when the Handy Cap IP covers the entire exposed metal area. Uncovered areas should be protected with primerless Tapecoat or Royston tapes. Remove the narrow plastic release film to accommodate tool use for keyhole applications

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.3.3

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.3

HANDY CAPS REVISION 1 TYPICAL PROPERTIES: Construction Molded plastic dome filled with corrosion resistant compound on a base of thick elastomeric tape.

Dimension:

Overall: 4” x 4”

Plastic Sheet:

2.75” x 4” (serrated)

Sheet Thickness:

10 mils

Plastic Dome:

1.625” diameter/ .8” height  

Adhesive Thickness:

165 mils

Weight:

2.8 oz

Appl Ap plic icat atio ion n Tem Tempe pera ratu ture re::

-20˚ -2 0˚F F to to 120 120˚F ˚F ((-29 29˚C ˚C to 49 49˚C ˚C))

Ser vi vice Te Temperature:

-40˚F to to 15 150˚F ((-40˚C to to 66 66˚C)

Shelf Life:

Rotate yearly  

DATASHEET 4.3.3

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.3.4

CABLE LUGS REVISION 1  APPLICATION Termination of positive, negative , test and reference electrode cables.

Bell Entry Copper Tube Terminals

i. In accordance with the codes of practice as directed by BS7609 (1992) ii. finish electro tinned to BS1872 (1984) iii. Copper Conductivity to 99.9% I.A.C.S. iv. Copper tube double annealed to BS2871 Part 2 ( C101)  v. Working temperature up to 180°C (Standard)  vi. Working temperature, with nickel plating, up to 350°C (Special)

All Copper Tube Terminals have a radiused entry  Typical sizes detailed below, below, full range available upon request. Part No

Cable Size Stud Size sq mm mm dia

ØA (mm)

B (mm)

D (mm)

ØE (mm)

F (mm)

G (mm)

H (mm)

J (mm)

K  (mm)

DX10-8

10

8

4.5

12

12

8.4

1.03

6

9

27

3

DX10-10

10

10

4.5

12

19

10.5

1.8

10

10

35

3

DX16-8

16

8

5.5

15

11

8.4

1.31

6

9

34

4

DX25-8

25

8

7

15

16

8.4

1.6

10

11

40

4

DX25-10

25

10

7

15

16

10.5

1.6

10

10

39

4

DX35-10

35

10

8.6

18

16.2

10.5

2

9

11

43

5

DX50-10

50

10

9.6

23

17.5

10.5

2.4

10

10

49

6

DX70-12

70

12

11.2

23

21.5

13

3

11

11

52

7

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: cpc@cathodi [email protected] c.co.uk Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.3.4

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.4.1

PIPELINE CASING INSULATORS REVISION 1  APPLICATION Carrier Pipe to Casing Insulation for crossings, suitable for Concrete Pipe, Ductile Iron Pipe, Plastic Pipe, Steel Pipe

PIPELINE CASING INSULATORS DATA  DATA 

Designed for 19mm to 122cm and larger nominal diameter carrier pipes. Casing isolators shall be PSI PE segmented  type, moulded in high density polyethylene plastic. Each isolator segment shall be a solid, "non-welded" moulded piece designed for accommodating variable pipe O.D.'s by  attachment of the required number of segments. Minimum isolator width shall be 76.2mm. Runner height shall be 24mm, 34mm or 48mm to provide adequate pipe support without the bell or joint contacting the casing during installation. Load carrying capacity per isolator shall be 340kg. The maximum load bearing capacity per isolator is based on 1.42 skid height in a cylindrical casing.

STEEL PIPELINE INSULATORS SPECIFICATIONS Band 14 gauge (2.0mm) steel. Two piece through 91.4cm carrier size with deep embossed flanges and corners cut at angles greater than 90-degrees. Liner (Optional)

Polyvinyl Chloride Thickness

2.29mm min

Hardness

Durometer "A" 85-90

Dielectric Strength 3.18 3. 18mm mm th thic ickk - Sur Surge ge Tes estt

60,0 60 ,000 00 V. Min Min

Step-by Step Test

58,000 V. Min

Water Absorption

1% max

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.4.1

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.4.1

PIPELINE CASING INSULATORS REVISION 1 Risers 10 gauge steel (3mm) MIG welded to band.

Runners 17.8cm Long x 5.1cm Wide Tensile Strength .................. (ASTM D638) .................. 17,600 psi Flex Strength ...................... (ASTM D790) .................. 25,300 psi Compression Strength (10% def.) ..........................(ASTM D695) .................. 18,000 psi Deflection Temperature @ 264 psi ..........................(ASTM D648) .................. 205 ºC.

MODEL PE PLASTIC PIPELINE INSULATORS SPECIFICATION Dielectric St Streng ngtth (A (ASTM D1 D14 49) :

550 V/ V/mil

Hardne nes ss Sho horre D (ASTM D1706) :

70

Comp Co mpre ress ssiv ive e St Stre reng ngth th (A (AST STM M D69 D693) 3)

3,20 3, 200 0 psi psi

Tens ensile ile Str Streng ength th (AS (ASTM TM D638 D638,, D651 D651))

3,100 3,1 00 - 5,50 5,500 0 psi psi

Water Absorption (ASTM D570)

0.1%

Temperature

82ºC.

Impact Strength (A (ASTM D2 D256)

105 - 2. 2.0 ft. ib ib/in. no notch

Band Width and Loading 76.2mm wide band

340kg/isolator

101.6mm wide band

907.2kg/isolator

127mm wide band

1,134kg/isolator

158.8mm wide band

1,134kg/isolator

Colour

Natural

Bolts and nuts

Cadmium Plated Steel

DATASHEET 4.4.1

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.4.2

LINK SEALS REVISION 1  APPLICATION Link-Seal® mechanical seals are considered to be the premier method for permanently sealing pipes of any size passing  through walls, floors and ceilings. In fact, any cylindrical object may be quickly, easily and permanently sealed, as they  pass through barriers, by the patented Link-Seal design.

LINK SEAL DATA 

Ductile iron, concrete, metal as well as plastic pipes may be hydrostatically sealed within walls to hold up to 20 psig (40 feet of head). Electrical or telecommunications cables may be sealed within conduit as they enter vaults or manholes. The annular space between carrier pipes passing through casings may be sealed against the entry of water, soil or backfill material. With a wide variety of hardware/ elastomer combinations, Link-Seal mechanical seals are easily configured to achieve the best possible match for service conditions encountered. Saves time and money...Link-Seal mechanical seals install in up to 75% less time compared to lead-oakum joints, hand fitted flashings, mastics or casing boots. Positive hydrostatic seal...Link-Seal mechanical seals are rated at 20 psig (40 feet of head), which exceeds the performance requirements of most applications. Long seal life...Link-Seal mechanical seals are designed for use as a permanent seal. Seal elements are specially  compounded to resist aging and attack from ozone, sunlight, water and a wide range of chemicals. Maximum protection against corrosion...Standard fasteners with a two-part organic resin coating or corrosion resistant  316 stainless steel. Certification/Approvals...Factory Mutual Fire Approvals. Det Norske Veritas Marine Deck/Bulkhead Penetration Certification. ANI (American Nuclear Insurers). Also a wide variety of approvals from various Federal agencies, associations, code groups, laboratories and organizations. ISO Quality Assurance...Link-Seal mechanical seals are manufactured in an ISO 9002 certified facility. Configure a Link-Seal to match your application...Colour coded EPDM, Nitrile, & Silicone elastomers may be used with  various hardware options to match performance characteristics with service conditions

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VA VAT T No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 4.4.2

PIPELINE EARTHING & ISOLATION ACCESSORIES

DATASHEET 4.4.2

LINK SEALS REVISION 1

DATASHEET 4.4.2

 Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098