G-JOINT - Monolithic Insulating Joints

GALPERTI TYPE G-JOINT®, MONOLITHIC INSULATION JOINTS

Within the range of branded products manufactured by The Original Galperti Group, the Monolithic Insulating Joint
G-joint® has now become a certain reference point.
Its use is to electrically isolate sections of a pipeline to ensure full efficiency to cathodic protection systems against
corrosion.
G-joint® is fully home-made, engineered, manufactured and tested by Galperti Tech Forged Products S.p.a., in
compliance with major international standards and more specific project requirements.

WHY TO USE MONOLITHIC INSULATION JOINTS ON PIPELINES

Dangerous leaks, contamination, pollution, service interruptions, pressure rating reduction, are all usual causes of
corrosion on both buried and above-ground pipelines. Metallic contacts and direct connections to earthing systems
should be avoided, or the risk of corrosion can be increased. As also strongly recommended by the ISO Internationl
Code 15589-1:2015, isolation should be achieved by installing the monolithic isolating joints as connections through
pipes, by avoiding all the related damages and costly drawbacks that would be due to their non-use.

BENEFITS AND ADVANTAGES

Installed on behalf of flange’s kit connections for certain lengths down the pipeline, the Monolithic Insulation Joints
grant the cathodic protection and several other advantages, like:
- Electrical break between the pipeline sections and neighbouring structures
- Reduction on Ground Loops Currents
- No loss of integrity due to thermal expansion or ground stress
- Supplied ready for easy installation
- No specific maintenance required

APPLICATIONS
- Existing and new constructions
- Oil & Gas, LNG, Hydrogen and Water lines
- To and from Gas distribution stations
- On Gas or Liquid fuel tanks
- On Subsea applications
- Onshore and Offshore, above ground and buried

APPROVALS AND CERTIFICATIONS

Galperti Tech Forged Products Spa. is accredited with the ISO 9001:2015 Certified Quality System, which means
having a close and focused control all over the manufacturing activities.

Galperti Tech Forged Products Spa. obtained the PED certification to manufacture and supply their monolithic
insulating joints from 4” to 56”, up to #2500 ANSI pressure class, Design Temperature -46°C / +110°C Fluid Group
1/2, according to the Pressure Equipment Directive n°2014/68/EU for pressure equipment, applying the CE marking
on their G-joint® product.
DATASHEET FOR MONOLITHIC INSULATION JOINTS
DESIGN CODE ASME VIII Div.1 - ASME B31.3/B31.4/B31.8
DESIGN FACTOR 0.6 1
SIZE RANGE From 4" to 56" 1
PRESSURE RATING From PN 20 to PN 420 1
ANSI CLASS From #150 to #2500 1
DESIGN TEMPERATURE From -46°C to +110°C 1
END CONNECTION BW - Butt Weld 1
CORROSION ALLOWANCE As per customer specification
EXTERNAL LOADS Axial, Shear, Bending and Torsional as per customer specification
FINITE ELEMENTS ANALISYS Upon request

INSTALLATION Abovegroung/Underground/Subsea - On-shore/Off-Shore

SERVICES NON SOUR / SOUR / TOXIC / LETHAL
FLUIDS OIL / GAS / HYDROCARBONS / CHEMICAL / WATER

FORGED MATERIALS Carbon steel, Alloy steel, Stainless steel, Duplex & Superduplex
PUP-PIECES MATERIALS Carbon steel, Alloy steel, Stainless steel, Duplex & Superduplex
INSULATION MATERIAL Epoxy glass according to ASTM D709, Type IV, Group G11
O-RING GASKET MATERIALS Elastomers NBR or FKM according to ASTM D2000
FILLER MATERIAL Two-components epoxy resin
SEALANT Silicone

INTERNAL COATING First layer: Epoxy Primer. Final layer: polyurethane top coat. 1
EXTERNAL COATING First layer: Epoxy Primer. Final layer: polyurethane top coat. 1

WELDING PROCEDURES According to ASME IX or ISO 15614

CERTIFICATIONS EN 10204 3.1 (3.2 upon request)

MECHANICAL TESTS Tensile, Impact and Hardness Tests (on forgings and pup-pieces)
NDE TESTS VT, PT, MT, UT, RT (on forgings, pup-pieces and welds)

HYDROSTATIC TEST 1.5 times Design Pressure 1

DIELECTRIC STRENGTH TEST 3÷5 KV 50Hz AC for 1 minute 1
ELECTRICAL RESISTANCE TEST > 5 MW with 1 KV DC in dry condition 1
HYDRO-BENDING TEST Upon request (on assembly) 75% SMYS pipe 1
TORSIONAL TEST Upon request (on assembly) 5% SMYS pipe 1
HYDRO FATIGUE TEST Upon request (on assembly)
PNEUMATIC AIR TEST Upon request (on assembly)
VACUUM TEST Upon request (on assembly)
PIGGABILITY TEST Upon request (on assembly)
IMMERSION TEST (3% saline) Upon request (on assembly)
HIC TEST Upon request (on forgings and pup-pieces)
SSC TEST Upon request (on forgings and pup-pieces)
CTOD TEST Upon request (on forgings and pup-pieces)
ADHESION TEST Upon request (on coating)
HOLIDAY TEST Upon request (on coating)

PED CERTIFICATION Upon request

EXTRAS Connectiong lugs and sparking gaps upon request

Note 1 : Standard production; other options available upon request.

COMPONENTS
- Pup-piece, is a pipe segment with
bevelled ends. Type
Type A
A Epoxy
Epoxy resin
resin
Dielectric
Dielectric Ring
Ring
Flange Retaining
Retaining ring
ring
Flange Connecting
- Boltless body, made by forged Epoxy Connecting Lug
Lug
Dielectric
Dielectric ring
ring Epoxy resin
resin
parts, insulating and filler Pup-piece
Pup-piece Flange Sealant
Sealant Pup-piece
Flange Pup-piece
material.
- Retaining ring Girth
Girth
Girth weld
weld Girth weld
weld
- Forged rings Closure O-Ring
Closure weld
weld O-Ring

- Dielectric ring
- Seal gasket O-Ring
- Epoxy resin
- Sealant
- Connecting lug
(available upon request)
Connecting lug is suitable Type
Type B
B Epoxy resin
Epoxy resin Dielectric Ring
Dielectric Ring
for bolted cable connection Flange Retaining ring
Retaining ring
Flange Connecting Lug
Lug
Dielectric ring
ring Epoxy resin
resin Connecting
and is intended for electrical Dielectric Epoxy
Pup-piece
Pup-piece
measurement or for a surge Flange Sealant
Sealant Pup-piece
Flange Pup-piece
diverter installation.
- Spark-gaps Girth weld
Girth weld Girth weld
Girth weld
(available upon request) Closure weld
weld O-Ring
O-Ring
Closure

DESIGN AND TECHNICAL DATAS

Galperti branded Monolithic Insulation Joints are designed in accordance with ASME VIII and applicable codes (ASME
B31.3 ASME B31.4 ASME B31.8). Standard calculations “by formula” are performed in accordance with ASME VIII
Div.1 App.2. The standard Design Factor considered and applied is 0,6, any different one is considered upon request.
Finite Element Analysis is also available on request, by ANSYS code.

They are currently covering ranges of manufacturing from 4” to 56” pipe size, from #150 to #2500 pressure class
ANSI (greater pressures are available upon request).

G-joint® is generally produced based on the above two standard designs, Type-A and Type-B.
The two typologies differ in the way the forged body is made and assembled; on a Type-B G-joint® the closure
welding on the external surface of the body is properly designed to carry out X-Rays, something not feasible on
Type-A joints (Ultrasonically tested, instead).
STEEL MATERIALS
Excluding the isolating components, the body of any insulation joint is made up of forged parts of several grade of
steel, according to the ASTM classification.
Pup-Pieces are generally made from the same API 5L material of the pipeline the insulating joints are studied to be
installed on; that’s also why, most of the time, they are “free-issued” from the user or the end-customer to Galperti,
the producer, also coming from stock and representative of the same mother pipeline.
According to the project requirement they might be made by forging too.

Common grades of steel used are Carbon steel, Low Tenor Carbon steel, Alloy steel, Austenitic & Martensitic stainless
steel, Duplex and Super Duplex stainless steel and Nickel alloys.

SEALING AND ISOLATING MATERIALS

Seals of aging resistant material from nitrile (NBR) or fluoride (FKM) in accordance with ASTM D-2000.
To ensure complete insulation, the dielectric material used are Epoxy-glass laminates or epoxy-glass prefabrications,
in accordance with ASTM D709, Type IV Group G11.
Filler material: a two-component epoxy resin is used to fill in the internal part of the joint.

TESTING
All the following standard tests are performed at Galperti Tech Forged Products premises:

- Mechanical tests (on Pup-Pieces and Forging Material)

- Non-Destructive Testing (on Pup-Pieces, Forging Material and Welding)
- Hydrostatic Pressure Testing (typically 1.5 times the rated pressure)
- Electrical Resistance Testing
- Dielectric Strength Testing
- Dimensional Checks

Upon specific request and according to the several technical requirements of major Projects, any G-joint® is also
subject to the following non-standard tests:

- Torsional (on the assembly)

- Bending + Hydro (on the assembly)
- Hydrostatic Fatigue (on the assembly)
- Pneumatic (on the assembly)
- Vacuum (on the assembly)
- Saline solution immersion (on the assembly)
- Piggable / Drift (on the assembly)
- HIC, SSC, CTOD (on pipes and forgings)
- Adhesion (on coating)
- Holiday (on coating)

Tests are usually conducted and certified EN 10204 3.1, or eventually 3.2 certified by general official third parties, or
by customer himself.
FOCUS ON TESTING
Electrical Resistance (in dry conditions)
The electrical resistance is normally measured by applying a voltage of 1KV DC. The guaranteed electrical resistance
is of 5 MΩ; a greater resistance is available upon request.

Dielectric Capacity
Our standard Monolithic Insulation Joins are capable to withstand a dielectric strength test without puncture of
coating and formation of sparks by applying a voltage, typically up to 5KV AC with 50Hz for 1 minute.
Dielectric capacity greater than the above available upon request.
Without any specific request from the customer or the project, 3KV with 50Hz for 1 minute is the standard
resistance proposed.

WELDING
Welding activities are carried out in accordance with ASME IX or ISO
15614 rules, and certified by independent and International Authorities. All
welds are then examined by Dye Penetrant, Magnetic Particle, X-Ray and
Ultrasonic testing.

COATING
Coating on internal and external surfaces shall be composed by a first layer of Epoxy Primer and a final polyurethane
top coat, and shall be suitable for the maximum design temperature of the pipeline.
Coating is always complying to the customer and project’s requirement. As alternative the G-joint® is supplied with a
thin thickness of preservative Anti-Rust Oil.
 Edition November 2023
OFFICINE NICOLA GALPERTI E FIGLIO S.P.A. GALPERTI ENGINEERING OFFICINE NICOLA GALPERTI E FIGLIO S.P.A.
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OFFICINE NICOLA GALPERTI

E FIGLIO S.P.A.
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22010 - Gera Lario (CO) Italy
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Fax. +39.0344.97210
www.galperti.com - galperti@galperti.com
GALPERTI TECH OFFICINE NICOLA GALPERTI E FIGLIO S.P.A.
FORGED PRODUCTS S.P.A. - ITALY FORGING PLANT II - ITALY
GALPERTI ENGINEERING
AND FLOW CONTROL S.P.A.
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23823 - Colico (LC) Italy
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Fax. +39.0341.930777
galpeng@galpeng.com

GALPERTI TECH
FORGED PRODUCTS S.P.A.
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