Experience Counts!   ElectroStop™ Isolating Fittings Description Benefits/Features Specifications Warranty Installation How to Order Typical Specification Resources Related Products Description Standard Tests Include: 100% Hydrostatic Pressure & Electrical Tests 100% Ultrasonic of Welds 100% Magnetic Particle of Welds 100% Dye Penetrant of Welds Benefits/Features Eliminates short circuits. Eliminated field assembly. Eliminates maintenance. Is less expensive. Is coated both internally and externally. Is 100% electrically tested. Is completely weld inspected. Is manufactured in accordance with ISO9001:2000 specifications. Sizes Available in any diameter. Available in any ANSI Classe & Stocked in ANSI Classes 150#, 300-400# and 600#. Standard Specifications 150# ANSI CLASS (PN or DP 25) 150# ANSI Pressure Rating = 285 psi ElectroStop Continuous Operating Pressure = 355 psi Test Pressure = 540 psi Working Temperature: Range = 14º F. to 212º F. (-10º C. to 100º C.) Electrical Resistance (Dry Air) = 25 Mohms @ 1kv D.C. Breakdown Voltage (Dry Air) = 5kv @ 50Hz for 1 minute. * See Note. 300-400# ANSI CLASS (PN or DP 64) 300# ANSI Pressure Rating = 740 psi 400# ANSI Pressure Rating = 990 psi ElectroStop Continuous Operating Pressure = 990 psi Test Pressure = 1,500 psi Working Temperature: Range = 14º F. to 212º F. (-10º C. to 100º C.) Electrical Resistance (Dry Air) = 25 Mohms @ 1kv D.C. Breakdown Voltage (Dry Air) = 5kv @ 50Hz for 1 minute. * See Note. 600# ANSI CLASS (PN or DP 100) 600# ANSI Pressure Rating = 1,480 psi ElectroStop Continuous Operating Pressure = 1,480 psi Test Pressure = 2,225 psi Working Temperature Range = 14º F. to 212º F. (-10º C. to 100º C.) Electrical Resistance (Dry Air) = 25 Mohms @ 1kv D.C. Breakdown Voltage (Dry Air) = 5kv @ 50Hz for 1 minute. Note: All data supplied is for standard fittings. Please contact factory for nominal diameters, pressures (up to 2500 ANSI), temperatures (up to 160° C, 320° F.) and electrical characteristics not shown. The information is subject to change at the manufacturer's discretion. Warranty All products are warranted against failure caused by manufacturing defects for a period of one year. Any product found to be so defective and returned within one year from date of shipment will be replaced without charge. The above warranty is made in lieu of, and we disclaim, any and all other warranties, expressed or implied, including the warranties of merchantability and fitness for a particular purpose, and buyer agrees to accept the products without any such warranties. We hereby disclaim any obligation or liability for consequential damages, labor costs or any other claims or liabilities of any kind whatsoever. Installation The ElectroStop™ Weld-in Monolithic Isolation Fitting Installation Guide The ElectroStop™ is a complete factory assembled and tested monolithic isolation fitting which will serve as a leak proof, long lasting block against the flow of electrical current in steel piping systems. Care should be used during the handling and installation process so as not to damage the fitting. Only two (2) welds are required for installation. The ElectroStop™ may be installed either above grade or buried below grade. Note: WHEN INSTALLING IN A VERTICAL POSITION ABOVE GRADE, THE WELDED END OF THE COLLAR (HUB) SHOULD FACE UP. The end filled with the epoxy fill (opposite end of the welded collar of hub) can have a concave area and possibly retain moisture and can be sensitive to ultra violet light exposure. THE SUGGESTIONS BELOW SHOULD NOT PRECLUDE FOLLOWING OF ALL COMPANY, LOCAL, STATE, OR FEDERAL CODES AND/OR SAFETY REQUIREMENTS AND/OR REGULATIONS. DESIGN CONCERNS, INCLUDING ELECTRICAL SAFETY PRECAUTIONS, GROUNDING, MECHANICAL STRESSES, ETC. SHOULD BE ADDRESSED PRIOR TO USE OR INSTALLATION. ALWAYS WEAR PROPER SAFETY EQUIPMENT FOR PERSONAL PROTECTION. CONSULT WITH YOUR COMPANY. The ElectroStop™ fitting should be installed just like any other weld-in fitting or piece of pipe with the only exceptions being: The temperature of the collar (hub) should not exceed 212 degrees Fahrenheit (100 degrees Celsius). Piping being attached to the ElectroStop™ must be properly aligned so as not to put undo mechanical stresses on the ElectroStop™. The pipe pups on the ElectroStop™ are intended to act somewhat as a heat sink and should not be shortened. If the fitting is too long for the installation location, cut the needed length out of the existing piping, not the ElectroStop®. During the welding operation a temperature sensor such as a thermometer or thermocouple should be secured to the collar (hub) of the ElectroStop™. As a precautionary procedure, wet rags or other cooling methods are sometimes used to reduce heat at the collar (hub) area. COATING After the welding operation is completed, The ElectroStop™ fitting and welds should be prepared for your corrosion protection coating or tape just like any other bare or shop coated fitting or piece of pipe. SUPPORT AND BACKFILLING Care should be used to assure uniform support and compaction around the entire ElectroStop™ fitting. Undo mechanical stresses caused by improper support or backfilling could cause damage to the ElectroStop™ that could result in leakage. TESTING AND CERTIFICATION All ElectroStop™ fittings undergo a weld inspection with combinations of ultrasonic (UT), magnetic particle (MT) and dye penetrant (LT) on all welds. X-Ray tests are preformed upon request. We certify that each standard order ElectroStop™ will be factory tested at 1-1/2 times the rated operating pressure for the amount of time listed below and in accordance to the latest ANSI Standards. Pipe Size Hydrostatic Minimum Test Time Up to 3" 15 minutes 4" 30 minutes 6" - 8" 1 hour 10" - 16" 2 hours 20" - 24" 12 hours Above 24" As required by each specification. After completion of the hydrostatic tests, The ElectroStop™ are electrically tested to assure an electrical resistance of 25 Mohms (wet or dry conditions @ 20( C) @ 1kv D.C. and a minimum breakdown voltage of 5kv @ 50 hz for 1 minute. Control over all stages of production is ensured by close adhearance to an in-place and ongoing ISO 9001 Quality Assurance Program which is constantly monitored and subject to periodic outside audit. A qualified inspector witnesses all tests. CALL PSI @ 1-800-423-2410 OR 713-747-6948 IF YOU HAVE ANY QUESTIONS. How To Order To order ElectroStop™ Monolithic Isolating Fittings please indicate the following: Quantity Nominal Pipe Size ANSI, DIN, API Pressure Class or Actual Working Pressure Pipe Grade Wall Thickness Temperature Limits Product Conveyed Contact your local distributor or Pipeline Seal & Insulator, Inc. Click here for dimensional data. Distributor Locator Contact PSI Typical Specification PSI ElectroStop™ Monolithic Isolating Fitting Standard Specification and Standard Design Specification STANDARD SPECIFICATION: Monolithic isolation fittings shall be boltless and completely factory assembled in accordance with the appropriate requirements of ASTM, API, DIN and BS codes. All welds shall be butt weld construction. The dielectric isolation material shall be a thermosetting fiberglass epoxy material. Sealing shall be by two (2) static, self energized “O” ring seals housed in accurately machined grooves, fully protected from cavitation in full compliance with ASME design codes. Interior and exterior coating shall be a two part epoxy with a thickness of 12 to 15 mils to within 2” of each end. Testing shall be Electrical (@5kv, 25 Mohm), Hydraulic (@ 1.5 x O.P.) and Weld (Ultrasonic/Magnetic Particle/Dye Penetrant). The Monolithic Isolation Fitting shall be the ElectroStop™ Isolation Fitting as manufactured by Pipeline Seal & Insulator, Inc., Houston, Texas. Quality Assurance Each monolithic isolation fitting shall be manufactured at a facility that has a Registered ISO 9001:2000 Quality Management System. Copy of current ISO 9001:2000 Registration shall be provided with material submittal. STANDARD DESIGN SPECIFICATIONS: ElectroStop™ isolation fittings provide permanent electrical isolation of piping sections, facilitating the management of a cathodic protection system. These fittings will be completely factory assembled. Design Features A low uniform profile enhances ease of handling and field coating or tape wrapping. Fittings can be welded into the pipeline above grade, utilizing standard pipeline welding procedures, then lowered into the trench by a sling. There is a natural heat sink to dissipate circumferential weld heat during installation. They are tamper proof and maintenance free after installation. Each fitting will be the following minimum length which will include the insulating mechanism and pipe pups. See provided charts. Literature contains more sizing information. 150# ANSI Class Nominal Diameter Inches (mm) Minimum Length Inches (mm) 2" (50.8) 27.5" (698.5) 3" (76.2) 27.5" (698.5) 4" (101.6) 27.5" (698.5) 6" (152.4) 27.5" (698.5) 8" (203.2) 27.5" (698.5) 10" (254.0) 31.5" (800.0) 12" (304.8) 39.33" (999.0) 16" (406.4) 35.43" (900.0) 20" (508.0) 39.37" (1000.0) 24" (609.6) 39.37" (1000.0) 30" (762.0) 39.37" (1000.0) 32" (812.8) 39.37" (1000.0) 36" (914.4) 47.24" (1199.9) 40" (1016.0) (As Specified) 42" (1066.0) (As Specified) 46" (1168.00) (As Specified) 48" (1219.0) (As Specified) 300-400# ANSI Class Nominal Diameter Inches (mm) Minimum Length Inches (mm) 2" (50.8) 27.5" (698.5) 3" (76.2) 27.5" (698.5) 4" (101.6) 27.5" (698.5) 6" (152.4) 27.5" (698.5) 8" (203.2) 27.5" (698.5) 10" (254.0) 31.5" (800.0) 12" (304.8) 39.33" (999.0) 16" (406.4) 39.37" (1000.0) 20" (508.0) 47.24" (1200.0) 24" (609.6) 47.24" (1200.0) 30" (762.0) 47.24" (1200.0) 32" (812.8) 51.18" (1300.0) 36" (914.4) 51.18" (1300.0) 40" (1016.0) (As Specified) 42" (1066.0) (As Specified) 46" (1168.00) (As Specified) 48" (1219.0) (As Specified) 600# ANSI Class Nominal Diameter Inches (mm) Minimum Length Inches (mm) 2" (50.8) 27.5" (698.5) 3" (76.2) 27.5" (698.5) 4" (101.6) 27.5" (698.5) 6" (152.4) 27.5" (698.5) 8" (203.2) 27.5" (698.5) 10" (254.0) 31.5" (800.0) 12" (304.8) 39.33" (999.0) 16" (406.4) 39.53" (1000.0) 20" (508.0) 47.24" (1200.0) 24" (609.6) 47.24" (1200.0) 30" (762.0) 51.18" (1300.0) 32" (812.8) 51.18" (1300.0) 36" (914.4) 51.18" (1300.0) 40" (1016.0) (As Specified) 42" (1066.0) (As Specified) 46" (1168.00) (As Specified) 48" (1219.0) (As Specified) The minimum bore of each fitting will be equal to the standard bore tolerances of the pipe in which it will be installed. Each fitting uses a method of closure that will positively maintain a pre-stressed load on the insulation section that is in excess of the end loading forces at test pressure. This is accomplished by weld closure. The insulating member will be fiberglass reinforced thermosetting epoxy resin. The sealing gasket will be Butadiene/Acrylonitrile rubber conforming to ASTM D2000. MANUFACTURING AND MATERIAL SPECIFICATIONS: Manufacturing The ElectroStop fittings described in this proposal will be manufactured to meet the material and manufacturing requirements established in the specification. These fittings will be manufactured in accordance with the most recent applicable ANSI, API, DIN or JIS standards as specified. The qualification of welders, their examination and registration will be conducted according to API 1104 or DIN 8560. All welding processes and procedures will be performed in accordance with API 1104 or DIN 8560. Welding Procedure: The forging of these fittings will be connected to the pipe pups by welds whose root passes are deposited by the manual inert gas (MIG) arc welding process. The balance of welds will be made by submerged arc process. Material Specifications All steel components supplied by the manufacturer and used in the fabrication of these fittings will meet the customer's requirements. This compliance will be validated by the submission of Mill Certificates giving the chemical and physical properties, if requested. The sealing elements will be fabricated from Butadiene/Acrylonitrile Rubber. The insulating gasket will be stratified epoxy resin with fiberglass or an equal material. Both interior and exterior coatings will be 2-part epoxy. TEST PROCEDURES: All testing will be performed in accordance with the requirements of this specification. The manufacturer will supply certifying documentation to substantiate this fact, if requested. Steel Parts All steel components supplied by the manufacturer and used in the fabrication of these fittings will conform to ANSI, API, DIN or JIS standards substantiated by the submission of mill certificates listing physical and chemical properties, if requested. Dimensional Verifications All critical dimensions will be according to the drawings approved by the customer. These dimensions will be checked and approved during production by responsible supervisory personnel of the manufacturer. Variances from the agreed dimensions will be committed to drawings and these variances will be subject to the approval of the customer's inspector. Weld Procedure Will conform to ASME Section 9. Radiographic Testing The manufacturer will have a qualified inspector confirm the results and pass approval on the non-destructive radiography tests at the time of their completion. All radiographs will be delivered to the customer's engineering department coinciding with the fittings' shipment by the manufacturer, if requested and if applicable. Ultrasonic, Die Penetrant, MAG Particle Testing The weld end of the fittings will be ultrasonically tested to confirm the absence of laminations in the weld ends. The weld ends of the fittings will be submitted to die penetrant tests to confirm the absence of porosity in the weld ends. The manufacturer will have a qualified inspector confirm and approve the results of the nondestructive ultrasonic and die penetrant test and deliver these test results records to the customer's engineering department at the time the fittings are shipped, if requested and if applicable. Hydrostatic Testing The manufacturer will conduct a hydrostatic test on each unit at a pressure of 1.5 times the maximum, non-shock, service pressure ratings in accordance with ANSI B16.5. All hydrostatic tests will be performed so that the fittings are unrestrained and their ends are capped. We certify that each ElectroStop fitting will be factory tested at 1.5 times rated operating pressure for the amount of time listed below. Pipe Size Inches (mm) Hydrostatic Minimum Test Time Up to 3" (76.2) 15 Minutes 4" (101.6) 30 Minutes 6" (152.4) to 8" (203.2) 1 Hour 10" (254.0) to 16" (406.4) 2 Hours 20" (508.0) to 24" (609.6) 12 Hours Above 24" (609.6) As required by each specification. The manufacturer will have a qualified inspector witness, certify and pass approval on the results. The certifications will be supplied to the customer's engineering department at the time the fittings are shipped, if requested and if applicable. Electrical Testing Electrical resistance in dry air will not be lower than 25 Mohms. Breakdown voltage in dry air will not be lower than 5 Kilovolts. The electrical resistance of standard insulating joints is guaranteed to be greater than the value obtained from the following formula: R = P (L-20)/S Ohm In which: P = Water resistivity in Ohm - centimeters. L = Overall length of joint in centimeters. S = Cross sectional area of joint in square centimeters. The manufacturer will have a qualified inspector witness, certify and pass approval on the results. The certificates will be delivered to the customer's engineering department at the time the fittings are shipped, if requested and if applicable. Visual Inspection All surfaces will be free of nicks, dents, gouges, laminations, arc burns and other visible surface defects. Grinding to remove these defects is permissible but no reduction below the specified nominal wall thickness will be allowed. This will be verified by ultrasonic testing. NOTES: The 150# ANSI Class ElectroStop fitting is designed to operate continuously at 355 psi and tested at over 1.5 times that value. Many other 150# ANSI Class fittings are only designed to operate at 285 psi. The 300# ANSI Class ElectroStop fitting meets the 400# ANSI class rating. It can operate continuously at 990 psi and is tested at 1500 psi. The 400# - 2500# ANSI Class ElectroStop fittings are rated at the maximum continuous operating pressure listed for these class fittings. During construction, each ElectroStop fitting is end loaded to assure a monolithic action in actual field conditions. Custom Orders Custom ordered ElectroStop fittings are available for unique installations with specific requirements such as products, temperatures, materials and conditions. Custom orders are manufactured to meet the customer's requirements in grades of steel or stainless steel, seal element and electrical isolation materials. Quality Assurance Control over all stages of production shall be in accordance with an ISO 9001:2000 Quality Assurance Program which is constantly monitored and subject to periodic audit. All tests shall be witnessed by a qualified inspector. Fitting shall be the PSI ElectroStop isolation fitting as manufactured by Pipeline Seal & Insulator, Inc., Houston, TX The above information is for our standard design fitting. For special applications such as higher dielectric strength, temperatures or custom materials, please contact PSI. 100% X-ray can be performed if requested at time of order placement at extra cost. Material subject to change with-out notice. Resources ElectroStop® Isolating Fittings A 6 page brochure that includes all specifications and sizing information for the ElectroStop® Isolating Fittings. PDF File Size = 193KB. Related Products Gaskets Sealing Gaskets Isolating Gaskets Flat Gaskets Flange Isolation Kits