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Table of Contents

PART I INTRODUCTION ........................................................................................................ 4


1.1 Scope ............................................................................................................................................................4
1.2 General definitions ....................................................................................................................................4
1.3 Abbreviations ..............................................................................................................................................5
1.4 Guarantee.....................................................................................................................................................5
1.5 Quality Assurance / Quality Control Requirements ..........................................................................5

PART II ADDITIONAL ADCO’S REQUIREMENTS .............................................................. 6

1 GENERAL ......................................................................................................................... 6

2 ISOLATING JOINT COMPONENTS ................................................................................. 6


2.1 Ring Seals ....................................................................................................................................................6

3 DIMENSIONAL REQUIREMENTS .................................................................................... 7

4 LOADING REQUIREMENTS............................................................................................. 7

5 PRESSURE RATING ........................................................................................................ 7

6 STARTING MATERIAL ..................................................................................................... 7

7 TESTING AND INSPECTION ............................................................................................ 8


7.1 Non Destructive Testing...........................................................................................................................8
7.2 Chemical Composition .............................................................................................................................8
7.3 Hardness Testing .......................................................................................................................................8
7.4 HIC Testing ..................................................................................................................................................8
7.5 Hydrostatic Testing ...................................................................................................................................8
7.6 Air Leak Test................................................................................................................................................9
7.7 Hydrostatic Fatigue Test ..........................................................................................................................9
7.8 Torsional Tests...........................................................................................................................................9
7.9 Combined Hydro-Thermo-Bending Tests............................................................................................9
7.10 Vacuum Tests ..............................................................................................................................................9
7.11 Electrical Tests ............................................................................................................................................9
7.12 Gauging .......................................................................................................................................................10

8 INSPECTION DOCUMENT ..............................................................................................10

9 MARKING ........................................................................................................................10

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 2 OF 11
10 PREPARATION FOR SHIPMENT .................................................................................10

11 PURCHASER INSPECTION.........................................................................................10

12 COMPONENTS NOT COVERED BY ISO 15590-2 ..........................................................11

13 COATING .........................................................................................................................11

14 DOCUMENTATION ..........................................................................................................11

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 3 OF 11
PART I INTRODUCTION

1.1 Scope

This specification defines ADCO’s additional requirements that apply for


materials, design, manufacture, testing and supply of monolithic
isolating joints for use in pipelines in Sour service.

This specification shall be read in conjunction with the latest edition of


the following documents:

 SHELL DEP 31.40.21.31- “Pipeline Isolating Joints


(Amendments/Supplements to ISO 15590-2).

 ISO 15590-2: Petroleum & Natural Gas Industries – Induction


Bends, Fttings and Flanges for Pipelines transportation systems –
Part 2 : Fittings

All clauses of the above referred SHELL DEP shall be applicable unless
specifically modified / supplemented by this specification. Additional
requirements as indicated in this specification shall take precedence over
relevant sections of ISO and Shell DEP.

1.2 General definitions

COMPANY ADCO (Abu Dhabi Company for Onshore Oil Operations)

Wherever the word “Principal” is used in SHELL DEP, the same


shall be replaced by the word “COMPANY”, with the same
authorities / responsibilities as defined in SHELL DEP

CONTRACTOR The party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of the
project. Contractor includes its approved manufacturers, vendors,
suppliers and subcontractors. Requirements of this specification
shall be enforced at all levels of the contractor's procurement and
construction process. The company shall have access to all
contractor suppliers to the same extent as required of contractor.

VENDOR/ The Party (Parties) which manufactures and/or supplies materials,


MANUFACTURER/ equipment, technical documents or drawings and/or services to
SUPPLIER perform the duties specified by the COMPANY.

SUBCONTRACTOR Any person or persons, firm, partnership, corporation or


combination thereof (not being an employee of CONTRACTOR),
including vendors to whom any part of the works has been
subcontracted by CONTRACTOR

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 4 OF 11
SHALL Indicates a mandatory requirement

SHOULD Indicates a strong recommendation to comply with the


requirements of this document

1.3 Abbreviations
ADCO Abu Dhabi Company for Onshore Oil Operations
ADNOC Abu Dhabi National Oil Company
BEDD Basic Engineering Design Data
DEP Design & Engineering Practice
EPC Engineering Procurement and Construction
FEED Front End Engineering Design
FFD Full Field Development
ITP Inspection & Test Plan
MR Material Requisition
PQR Procedure Qualification Records
RDS Remote Degassing Station
TPI Third Party Inspector Agency. .
VDRL Vendor Document Requirement List
VQRF Vendor Quality Requirement Form
UAE United Arab Emirates
WAG Water Alternating Gas

1.4 Guarantee

MANUFACTURER shall bear all costs to seek, find, and repair all leaks
and/or ruptures which may occur during field hydrostatic testing, and
which result from defects traceable to the material / manufacture of
Isolating Joint. The field test will not exceed a pressure that will cause a
circumferential fibre stress greater than 95 percent of the specified
minimum yield strength of the connecting pipe.

1.5 Quality Assurance / Quality Control Requirements


MANUFACTURER shall establish and maintain a quality system in
accordance with ISO 9001:2008 and ADCO standard EP 30.99.97.0006.

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 5 OF 11
PART II ADDITIONAL ADCO’S REQUIREMENTS

1 GENERAL

 Design shall be offered for boltless, monobloc type isolating


joints for onshore applications. Isolating joints shall be installed
above ground.

 Isolating Joints shall be suitable for all types of pigging, including


intelligent pigging survey, wherever specified in the Isolating
Joint datasheet.

 Proven history of successful installations is a mandatory


requirement for each type and size of isolating joint offered.
MANUFACTURER shall also submit complete manufacturing
procedure with its proposal to COMPANY/CONTRACTOR.

 The joints shall be capable of withstanding the effects of a humid


salt laden atmosphere onshore without loss of performance.

 The design code and operating conditions are indicated in the


Isolating Joint Data Sheets.

2 ISOLATING JOINT COMPONENTS

 A double set of ring seals shall be provided for pipeline internal


pressure containment for all isolating joints.

 Testing of insulating materials shall be in accordance with ASTM


D695 or other relevant codes depending on the insulating
material to be used.

 The isolating joint components shall be manufactured by forging.

 A corrosion allowance, as specified in the Isolating Joint data


sheet, shall be considered in the design.

 Ring seals (flouro elastomers / per flouro elastomers) shall be


resistant to explosive decompression and shall be suitable for
long term exposure to the transported fluid at the specified
design pressure and temperature.

2.1 Ring Seals

 Ring seals in gas service shall be perflouro-elastomer seals


(Kalrez, zalak or approved equivalent). This is due to their higher
resistance to temperature and chemical degradation.

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 6 OF 11
3 DIMENSIONAL REQUIREMENTS

 Isolating joints shall be supplied with pup pieces welded at both


ends. Length of pup pieces shall be at least one Pipe Diameter.

 Pipe for pup pieces shall be compatible as the connecting line


pipe, as specified in the data sheet.

 The minimum overall length of isolating joints (including pup


pieces), for pipelines shall be as follows:

For 18” - 36” diameter : 2500 mm

For 16” and less diameter : 1600 mm

 Bevel ends shall be standard bevel, in accordance with ISO 3183


/API 5L and Shell DEP 31.40.20.37.

 The joint between pup piece and forging shall be full penetration
buttweld type. Post-weld heat treatment shall not be used for
field welding.

 MANUFACTURER shall confirm that the heat generated by field


welding is not detrimental to the isolating and filler materials and
internal / external coating.

4 LOADING REQUIREMENTS

The isolating joint assembly shall be capable of withstanding a


maximum bending moment during hydrostatic testing equivalent to that
required to induce a bending stress of 75% SMYS in the connecting line
pipe. The isolating joint shall be capable of withstanding a maximum
torsion stress of 5% SMYS in the connecting line pipe.
MANUFACTURER shall indicate maximum allowable external force and
moments for the offered isolating joints.

5 PRESSURE RATING

MANUFACTURER shall possess the design calculation and /or results


of relevant proof testing for fittings for the size range of isolating joints
for this order, which shall be furnished to COMPANY at proposal stage.
MANUFACTURER shall submit all design calculations for isolating joints
to be supplied under this order for COMPANY/CONTRACTOR approval
prior to commencement of fabrication. Fabrication shall commence only
after obtaining COMPANY’s approval on the design.

6 STARTING MATERIAL

Materials for isolating joints shall be suitable for sour service and shall
comply with requirements of NACE MR 0175 / ISO15156.

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 7 OF 11
Welding shall be in accordance with Shell DEP 61.40.20.30 and ADCO
amendment 30-99-00-0041.

7 TESTING AND INSPECTION

7.1 Non Destructive Testing

All butt welds shall be 100% radiographed.

The welding ends of each isolation joint shall be 100 per cent
ultrasonically examined over the entire circumference for a distance of
25 mm from each end.

All other welds and bevel ends shall be Magnetic Particle Inspected
(MPI).

Forgings shall be subjected to 100 per cent surface examination by MPI.

No repairs shall be permitted to isolating joints that have failed any of


the tests outlined in this specification.

7.2 Chemical Composition

The pipe sections used for isolating joints shall be identical to the
connecting pipeline material and shall be subjected to the same testing
requirements as required for the linepipe. The Chemical composition
shall comply with the requirements for pipe of the same grade and type
as specified in applicable ADCO standard for line pipe (ES-30-99-00-
0104/ ES-30-99-00-0105/ES-30-99-00-0106).

7.3 Hardness Testing

Hardness for base metal, weld metal and heat affected zone shall not
exceed 248HV10.

7.4 HIC Testing

HIC sensitivity testing to be performed for components fabricated from


plate or pipe. Test solution “A” as per NACE Standard TM0284 shall be
used. Method of testing, pH values, test duration and test temperature
shall be as per NACE Standard TM0284.

7.5 Hydrostatic Testing

Hydrostatic test shall be carried out at a test pressure 1.25 times the
design pressure with the fitting in unrestrained condition. Pressure shall
be held for 4 hours. There shall be no leakage or pressure loss during
the test.

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 8 OF 11
7.6 Air Leak Test

After hydrostatic testing, all isolation joints shall be leak tested with air at
10 bar g for 10 minutes. The tightness shall be checked by immersion or
with a frothing agent. No leakage shall be accepted.

7.7 Hydrostatic Fatigue Test

Hydrostatic fatigue test shall be carried out on each joint as follows:

a) Test Pressure: 80 percent of Hydrostatic Pressure Test (i.e. 80


percent of 1.25 x Design Pressure), Holding Time 10 (ten) minutes.

b) Reduce pressure to atmosphere level.

c) This test shall be carried out for 5 cycles.

The above test shall be carried out with bending moment applied as per
section 4 of this document. The bending moment shall be capable of
inducing a bending stress of 75% SMYS in the matching linepipe, when
combined with the longitudinal stress due to internal pressure.

7.8 Torsional Tests

One joint of each size shall be subjected to torque sufficient to induce a


torsional stress of 5% SMYS in the adjoining pup piece. There shall be
no relative rotational movement of the pup piece on completion of test.

7.9 Combined Hydro-Thermo-Bending Tests

Combined hydro-thermo-bending test shall be carried out for duration of


24 hours, as prototype test, i.e. per diameter and wall thickness.

 Joint shall be heated up to design temperature (100 deg.c for oil


service & 120 deg.c for gas service)

 Pressurise to design pressure and

 Subject to bending moment load as required by section 4 of this


document.

7.10 Vacuum Tests

A vacuum test of 5 millibar shall be conducted on each isolating joint,


irrespective of pipe diameter.

7.11 Electrical Tests

Electrical tests shall be done after hydrostatic pressure test.

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 9 OF 11
A voltage of 2000 V (AC) at 50 Hz shall be applied across the joint for 5
minutes. There shall be no breakdown, flash-over or reduction in
electrical resistance during this period.

7.12 Gauging

A gauging pig shall be passed freely through each isolating joint. The
gauging pig shall have two parallel 6 mm thick circular aluminium plates,
each a minimum of 97% of the nominal ID of the connecting pipeline,
separated rigidly by a bar of length twice the nominal ID of connecting
pipe.

8 INSPECTION DOCUMENT
The Certificate shall comply with BS EN 10204 Type 3.2.

9 MARKING

Markings shall be paint stencilled in 25 mm high or larger letters on the


outside surface at 100 mm from the end using a weather resistant paint
of contrasting colour.

In addition, marking shall be done by low stress die stamping. Die


stamping is permitted only on the weld bevel.

10 PREPARATION FOR SHIPMENT

The isolating joint assemblies shall be packaged so as to prevent


damage during shipping. Bevel ends shall be supplied with metallic or
high-impact plastic bevel protectors, of a type to be approved by
COMPANY. MANUFACTURER shall furnish the following information at
Bid stage:
 Protection of weld bevels against damage during shipment
 Physical protection of the test point connections
 External protection against corrosion
 Protection from damage during shipment

11 PURCHASER INSPECTION

COMPANY/CONTRACTOR reserves the right to carry out inspection of


the Isolating Joints during all stages of manufacture of the joints.
However, any inspection by the COMPANY / CONTRACTOR shall not
relieve the MANUFACTURER of his responsibility to supply isolating
joints in strict compliance with this specification.

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 10 OF 11
COMPANY’s Representative shall have free entry at all times to all parts
of the Works which concern the manufacture, testing, inspection, quality
control and shipping of the isolating joints ordered. MANUFACTURER
shall make available to COMPANY’s/CONTRACTORS’s Representative
without charge all reasonable facilities to carry out inspection and testing
at all stages of manufacture.

12 COMPONENTS NOT COVERED BY ISO 15590-2

Details of ring seals, insulating materials and filler materials, including


dielectric strength, compressive strength, dimensions and suitability for
use at the design temperature and pressure and long term exposure to
the fluid transported shall be furnished by MANUFACTURER at Bid
stage.

13 COATING

The isolating joint shall be coated internally to prevent electrical bridging


of the two spools through the transported fluid. The joint shall be coated
externally. The internal and external coating coatings shall terminate 50
mm from the joint ends.

All surfaces to be coated shall be blast cleaned to ISO 8501-1 grade Sa


2 ½.

The internal coating on the isolation joint shall be of suitably qualified


fusion bonded type based on epoxy/novolac coating chemistries as per
SHELL DEP 31.40.21.31- Gen. and shall be suitable for the specified
maximum design temperature the pipeline. External coating shall be as
specified in SHELL DEP 31.40.21.31-Gen.

The extended spool pieces for the isolating joints in the produced water
and WAG (Water Alternating Gas) water services shall be FBE lined in
accordance with project specification for internal FBE lining of Line pipe
and fittings.

Metallic pigmented coatings shall not be used.

Following the hydrostatic pressure test and electrical checks, the


coatings shall be subject to holiday detection using a wet sponge tester
set at 60 volts. The test method shall be approved by the COMPANY.
The acceptance level shall be zero holidays.

14 DOCUMENTATION
Documents and drawings shall be supplied in accordance with
requirements specified in material requisitions.

Project No.: MASTER


SUPPLEMENT TO
ADCO DOC. NO.: 30-99-23-0115
SPECIFICATION FOR PIPELINE
ISOLATING JOINTS REV. 1 DATE: Sept 2014

PAGE 11 OF 11