Corrosion is destroying approximately 30% of the world’s annual production of steel.  Where you find pipelines for gas an oil distribution system, you will also find a range of isolation joints.  The correct location of a monolithic isolation joint results in saving overall cost of corrosion control systems.

For onshore projects, an isolation joint is used to limit the spread and hence cost of cathodic protection current to those pipes that need to be effectively and economically protected by the main CP system.

An isolation joint is used to electrically “split up” long pipelines into distinctive system.  Or to isolate and ensure that CP or stray electricity currents do not cause increased corrosion.

Or to provide protection against earthing currents at domestic and industrial premises where the PME (Protection Multiple Earthing) system is in use.

Why using Monolithic Insulation Joints is the best choice for Engineering Pipeline Projects :

¨  Insulation Joints serve as a positive leak proof, long lasting block against the flow of electric currents in all piping systems, causing corrosion and leakeges.

¨  Eliminate Short Circuits: Bolt, Sleeves and Washers are the major cause of short circuits in most isolation assemblies are eliminated when using Monolithic Isolation Joints.

¨  Eliminates costly and time consuming field assembly: MIJs are completly factory assembled and tested. There are no flanges, gaskets, nuts, bolts, sleeves, or washers to handle and consequentially no fluid leaks due to improper field assembly.

¨  There is no possibility, as it happens where gaskets are used in flanges, of water infiltration and consequentially loss of insulting capabilities.

¨  MIJs can be purchased for less than the cost of components parts of insulated flange assemblies in most pipe sizes.

¨  You can install MIJs for much less than the labor costs of installing an insulated flange assembly.

General Characteristics:

1. Pre-Assembled and Pre-Tested
2. Saving on skilled on-site labour
3. No maintanance required
4. No Failure caused by improper installation.
5. No Pipeline shutdown because of failure, replacement or leakage.
6. Simplified serviceability and maintanance
7. Increases the safety of the pipeline
8. Increases the life duration of the pipelines
9. Drastically decreases the OVERALL project LIFE CYCLE COSTS.

Advantages on On-Shore Projects

¨  To limit the spread and hence the cost of cathodic protection to those pipes that need to be effectively and economically protected by the main cathodic protection system.

¨  To electrically «split up» long pipelines into distinctive cathodic protection system.

¨  To isolate a pipeline and top ensure that cathodic protection or stray electricity currents do not cause increased corrosion.

¨  To provide protection against earthing currents at domestic and industrial premises where the PME system is in use.

Advantages on Off-Shore Projects

¨  In riser pipes and offshore structures to isolate the pipeline cathodic protection system.

¨  At field «tie-ins».

Testing

In addition to standard tests, Isolation Joints can be Hydrostatically & Pneumatically tested in House

Upon customer specific requirements, Isolation Joints are able to be tested applying Bending Moment and Torsion Moment and Special Vacuum test.

Market of interest and applications

Due to the use of the highest grade of Carbon steel, forged steel, 316ss , 17.4 Ph, duplex alloys, and thanks to the improved design of scotch yoke actuators, actuator products are often found operating:

-          On offshore platforms located in the swirling North sea, in the Mediterranean, In South East Asia , in Asia, in Oceania , in the Gulf of Mexico and offshore Brazil

-          On gas pipelines in the middle east

-          On oil pipelines in the middle east

-          In desalination plants in aggressive brine applications in hot humid marine locations, in the Middle East and Europe

-          In cold artic conditions on gas pipelines and in far north plants

-          In PTA plants with corrosive environments

-          In LNG plants and on LNG carriers

-          In Petrochemical plants and Chemical plants located in Asia, South East Asia, North Africa and South Africa

-          In HIPPS applications

-          In Turbine trip applications 0.1 seconds fail safe

-          In Power plants modulating steam valves

-          In Water treatment plants

-          In solar power plants generating renewable energy

-          In shipbuilding both topsides and operating submerged ballasting valves

-          At the bottom of the sea

Quality

Actuator companies are in accordance with European directive 94/9/EC art. 8.1.b.ii group II category 2 – ATEX , the European Pressure Equipment Directive PED 97/23//EC and SIL certified.

Valve  & Actuator Testing

After position setting on free issued valves, all actuators and control systems are tested according to all standards requested and actuator manufacturer internal test procedures, which include: operational test, static and dynamic leakage tests and torque testing

Products-List

-          Pneumatic Actuators

-          Hydraulic  Actuators

-          Electro Hydraulic  Control Actuators

-          Gas Over Oil Actuators

-          Electric Actuators

-          High Integrity Pressure Protection System (HIPPS)

-          Sub Sea

-          Hydraulic Dampers

-          Control Systems

-          Instrument Gas Systems

-          Passive Fire Protection

 

Focus on HIPPS

High Integrity Pressure Protection System

The function of HIPPS is to protect the downstream equipment and to prevent the loss of containment against overpressure by closing the source

The loss of containment can result in:

impact to human life and the environment, when flammable, explosive, or toxic chemicals are released to the atmosphere

economic impact due to production unit replacement/repair costs and production losses

Independent and reliable systems, that shall operate on a higher Level than Process Shut Down and Emergency Shut Down.

Typical functional test for HIPPS actuation

-          Cylinder leak test

-          Piston Leak test

-          Actuator Cycling tests (available on request)

-          Complete functional test

-          Fail action speed checking

-          Leakage test (Duration)

-          Torque Tests

-          Performance test at min / max supply pressure

-          Operating under load test (available on request)

-          Performance after Cycling Test

-          Repeat pressure test

-          Visual inspection

-          Standard Oil Cleanliness level NAS 6 (other level if required)

 

Focus on Electro Hydraulic System

Electro hydraulic system is suitable for both on/off, total modulating service, partial stroke testing and can achieve an ultra fast fail safe stroke within < 200 ms by means of special integrated hydraulic discharge system complete with end of stroke hydraulic damper.

Technical details

-  ESD – Emergency Shut Down Operation

-  PST – Partial Stroke Test in Local/Remote mode

-  Output torque control by pressure monitoring

-  Manual override by means of integrated local hand pump

-  Free adjustable stroking times for open/close

An Advanced Intelligent Electro Hydraulic Control System allows specific valve angular position
control suitable for modulating service, partial stroke testing and normal ON/OFF operation as well as allowing a series of information exchange by means of status signals provided by power output contacts as described below:

-  General on-line availability

-  General fault message alarm

-  Motor operation signal

-  Motor failure alarm by motor circuit breaker

-  Hydraulic tank minimum oil-level alarm

-  Accumulator- Low – Hydraulic-Pressure alarm

-  Valve open position by SPDT switch

-  Valve close position by SPDT switch

-  Additional Signals can be added on request

IHP – Integrated Hydraulic Positioner provides based on standardized analogue signals fully modulating or simple ON/OFF service.

Turn key solution:

• Detailed Engineering

• Calculations & Studies

• Pre-Fabrication

• Coating

• Skid Mounting

• Testing

• Commissioning

• Start-Up

• Maintenance & Field Service

• Repairs, Calibration & Validation

• Spares Parts & Consumables

• Technical Support & Training