Using Flange Isolation Kits and Monolithic Isolation

Joints in Your Pipeline

Integrity Management System

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 Using Flange Isolation Kits and Monolithic Isolation Joints in Your Pipeline
Integrity Management System

The United States has more than 2.6 million miles of pipelines that are essential for the nation’s
economy. Pipelines deliver hundreds of billions of tons per mile of liquid petroleum products and
trillions of cubic feet of natural gas safely each year, which is well beyond the safe capacity of
other forms of transportation. The United States also contains over 1.3 million miles of water
pipelines and 1,600 miles of hydrogen pipelines.
Hazardous liquid pipelines transport crude oil; refined petroleum products such as gasoline, jet
fuel, diesel and home heating oil; highly volatile liquids or natural gas such as methane, ethane,
propane and butane; carbon dioxide; and anhydrous ammonia. Others transport water.

Unfortunately, there are approximately 50 pipeline failures and leaks every year – many of which
are associated with corrosion issues. According to Statista, pipeline failures in the United States
cost nearly $340 million in damages in 2020 alone – and that’s only in oil and gas pipelines.
The most common failure mode for a pipeline is, by far, corrosion. Corrosion occurs naturally
when a metal reacts with the environment such as oxygen or water. To learn more about pipeline
corrosion, read: An Intro to Pipeline Corrosion and Protection Methods.

Types/Causes of Corrosion

Various types of corrosion have been reported for pipelines, with the most common being:

• Uniform corrosion, which occurs uniformly over the entire metal surface.
• Galvanic corrosion, which occurs when two metals of different chemistry are in contact with
each other and moisture is present.
• Crevice corrosion, which is a localized attack adjacent to the gap or crevice between two
joining surfaces such as at a flange joint.
• Microbiologically induced/influenced corrosion (MIC), which occurs directly or indirectly from
the activity of microorganisms.

To learn more about types of corrosion that most commonly affect pipelines, read:
21 Types of Pipe Corrosion & Failure.

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 Corrosion Prevention for Pipelines

To reduce the risk of a pipeline corrosion failure, two approaches can be used: coatings or
cathodic protection. The former, coatings, can be divided into two major categories: external
coatings and internal coatings.

The following section explores coatings and cathodic protection slightly more in-depth.

External Coatings
To block the pipeline from coming in contact with the electrolyte,, external coatings are applied to
the exterior of the pipe to form a barrier between the pipe and soil/environment. Typical external
coatings can consist of bitumastic materials such as coal tar, asphalt or bitumen or epoxies and
other polyester materials. Requirements for external coatings include chemical resistance, UV
resistance and low moisture permeability. Hot coal tar is a common coating material that is often
covered with a paper wrap to protect it from damage prior to insertion into the ditch.

Internal Coatings
Oil and gas fluids can contain solid particulates such as sodium chloride, potassium chloride,
carbonates, sulfates, and partially polymerized oils that can remain in suspension. These
particulates might travel at speeds approaching 200 mph and can then become aggressively
erosive/corrosive projectiles. Internal coatings tend to be liquid epoxy or internal fusion-bonded
epoxy with low frictional resistance for increased hydraulic efficiency and corrosion resistance to
the fluid/gas constituents in the pipeline. To learn more about epoxy coatings, read:
New Advances in Epoxy Protective Coatings.

Cathodic Protection
Cathodic protection is a technique where a buried pipeline is made the cathode and another
metal is used as a sacrificial anode that preferentially gets corroded by the electrochemical
process rather than the pipe metal. The pipeline’s corrosion rate can be decreased by bringing the
galvanic potential of metal to the immune state to be protected. To learn more about cathodic
protection, read: The Basics of Cathodic Protection.

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Risk Assessment of a Pipeline
While both coatings and cathodic protection can minimize corrosion issues in a buried pipeline,
another layer of protection is to combine the coating with cathodic protection and reduce the
potential for corrosion and subsequent leakage. Adding an isolation device provides even further
protection by eliminating stray current from affecting the entire pipeline. This is where monolithic
insulation joints (MIJs) and/or flange isolation kits (FIKs) come in. Integrating MIJs and FIKs into
the pipeline is an excellent technique for controlling stray electric currents, which can increase
the effectiveness of the cathodic protection system as well as reduce the cost of the electricity
that is required to protect the pipeline.

The Need for Isolation Joints in Conjunction with Cathodic Protection

Both monolithic isolation joints (MIJ) and flange isolation kits (FIK) will isolate segments of the
pipeline; but MIJs are typically used for buried pipelines while the FIK is installed in above ground
pipelines. The concept is for MIJ and FIK to prevent electric current from flowing beyond a specific
distance with the objective of optimizing the cathodic protection. In addition, this approach
disrupts the stray current from dissimilar metals which stops electrochemical reaction or galvanic
corrosion between connected dissimilar metals.

Note that galvanic corrosion requires electrical conductivity between dissimilar metals; thus, even
if the dissimilar metals are not in contact but there is electrical conductivity such as by a stray
current, they are susceptible to causing stray current corrosion of the less noble metal. Dissimilar
metal parts in the pipeline include for example, valves, compressors, pumps, and meters. Their
small differences in chemistry for these components compared to the pipe metallurgy can be
sufficient for the potential of galvanic corrosion. Therefore, inclusion of MIJ or FIK between the
metal component and the pipe or at pipe-pipe connections is critical for eliminating the stray
current and mitigating the potential corrosion.

In addition, the incorporation of MIJs and FIKs into the pipeline can allow for a reduction in
electricity required for the cathodic protection that will result in less tendency for coating
disbondment and hydrogen induced type corrosion, as well as cost savings from the reduced
energy consumption.

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 Monolithic Isolation Joints

Monolithic isolation joints are most commonly used in buried pipeline applications and when a
pipe comes from underground to aboveground. MIJs can also be used aboveground to limit the
possibility of electrical bridging across the joint where it is girth welded between two pipe
sections. The use of MIJs eliminates the source of a short circuit by removing bolts, sleeves and
washers. Since there are no flanges, gaskets, washers, sleeves, or bolts, field assembly is not
required, which prevents any improper assembly. The joint consists on one side of a pipe
segment with a beveled end for welding to the pipeline and on the other side is a welded
bottomless flange for encapsulating the isolating and filler material. Because there are no
threaded components, they cannot be disassembled in the field.

From NACE RP0286

Construction and Design of Monolithic Isolation Joint

NACE RP0286 Standard Recommended Practice Electrical Isolation of Cathodically Protected
Pipelines describes the typical design of MIJ for high pressure applications (over 150 psi) with
double sealing rings and low pressure applications (below 150 psi) with a single sealing ring as
shown above. MIJs are designed to match the metallurgy and service conditions.

A good practice is to use an MIJ that meets the appropriate ASME code, such as ASME B31.3
Process Piping Guide, ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries,
ASME B31.8 Gas Transmission and Distribution Piping, and if the pipeline is considered pressure
containing ASME VIII Division 1 Rules for Construction of Pressure Vessels. The dielectric
isolation material is typically a high temperature thermosetting fiberglass epoxy.

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Note that not all epoxies have the same thermal mechanical properties. As shown in Table 1, the
softening of the epoxy at a specific temperature also referred to as the glass transition
temperature determines the strength or viscoelastic properties of the material at elevated
temperatures and establishes the maximum operating temperature. The ring seal can be a dual
static, self-energized O-ring seal housed in an accurately machined groove that is fully protected
from cavitation. Maximum temperature of operation will determine the selection of the polymer
for the elastomeric O-ring seal. Exceeding the temperature rating of the polymer can result in
compression set or permanent deformation, where the seal will not properly interface with the
sealing surface as intended and thus creating a leak path. Typical upper temperature ratings for
various common seals are provided in Table 3.

The MIJ may be coated both internally and externally at the factory with a non-conductive epoxy
for corrosion protection. All metallic components should be supplied with certified material test
reports to confirm their physical and chemical properties and selected with the same metallurgy
and yield strength as the pipe. For sour gas service (presence of H2S) the maximum hardness
allowed for steel pipe is 248HV (RC22) to prevent sulfide stress cracking or hydrogen cracking.
Typical quality assurance testing to ensure no failure of the MIJ during operation should include
electric insulation testing at for example 5 kv and 25 Mohm (lower voltages can be used but with
higher resistance), hydrostatic testing at 150% of operating pressure and ultrasonic or magnetic
particle non-destructive testing for weld cracks (ASME Section V).

Table 1: Glass Transition Temperature Table 2: Maximum Operating Temperature

for Commonly Used Glass Reinforced Epoxy for MIJ Seals

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Installation at Site
Since MIJs are fully factory assembled and ready for installation, they are factory inspected,
which includes electrical isolation and leak testing. Thus, they cannot be disassembled or easily
modified in the field.

An MIJ is typically wrapped with a volatile corrosion inhibitor and/or coated with a corrosion
inhibitor prior to shipment to site. MIJs must be treated carefully during handling and
transportation to prevent any mechanical damage or deformation as well as damage to the
internal and external coatings. During installation, the joint must be well supported with
strapping on both sides of the hub to prevent damage or deformation, which can then stress the
joint after welding the MIJ into the pipeline. During welding of the MIJ into the pipeline, the joint
should be kept cool with the body kept below about 212°F or below the maximum operating
temperature for the seal gaskets, isolating rings and coatings.

Resin and gaskets are sensitive to hard impacts from applied stresses and thus striking the joint
to align the pipe should be avoided. Each joint has a traceable serialized heat code identification,
which should be recorded in the appropriate log book. There is no preferred installation direction
with respect to fluid direction and can be installed horizontally or vertically. When installed in the
vertical orientation, the MIJ should be positioned with the side with the silicone filter facing
downward.

Flange Isolation Kits

Flange isolation kits (FIK) are another approach for sealing and electrically insulating from static
current metal to metal contact in a pipeline and thus mitigating corrosion by galvanic action when
used in conjunction with cathodic protection.

A FIK consists of gaskets to separate flanges in the pipeline along with non-conductive sleeves
and washers to prevent the flow of electric current across the connection. Materials of
construction are very dependent on service conditions. For example, a fire safe FIK is required if
the pipeline is carrying a flammable material such as methane. Chemical compatibility of the
isolation kit with chemicals added to the fluid/gas to reduce microbial colonies from forming, to
reduce scale formation such as iron sulfide, or surfactants must be fully investigated in order to
select the appropriate materials of construction.

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Types of Flanged Isolation Kits and Materials of Construction

A FIK consists of one washer for each nut, one full length insulating sleeve for each bolt, a gasket
and thick plated steel washers for each nut. There are four major types of gasket isolation kits,
designated as F, E, D, and O with each kit fitting flanges with specific faces. The flange face is the
surface that hosts the gasket. The specific faces include raised face flange, flat face flange or
ring joint flange and each requires a different gasket to prevent leakage at the joint. Different
flange types should never be mated because they cannot be sufficiently tightened to prevent
leaking. For example, a flat faced flange should never be mated with a raised face flange since
such a joint would most likely leak. Flat or raised flanges can have finishes that are smooth, stock
or serrated. Flange finish is often referred to as arithmetic average roughness height, which is the
average roughness height values and can be used to determine the combination and selection of
flanges and gasket materials.

The higher the average roughness height, the more rough the surface and vice versa the
smoother. Sealing performance for the flange gasket combination is directly related to the
roughness, flange dimensions, and the applied pressure of the stud bolts. Further information
about flanges can be found in ASME B16.5 Pipe Flanges and Flanged Fittings.

FIK F kits are designed with a raised flange face with the gasket designed to fit only on the raised
portion of the flange. There are no bolt holes in the type F gasket; the inside diameter of the bolt
hole circle is slightly smaller than the outside diameter of the gasket. This assures automatic
positioning of the gasket in the flange assembly. Wrapping the flange to prevent foreign material
from collecting and creating a bridge that shorts across the flange is often utilized. The type E
gasket for FIK E kits is designed to fit only the full-faced flange and is designed with the same
outside diameter as the flange. The precision cut and locations of the bolt holes facilitates the
exact alignment of the gasket during installation and prevents foreign material from shortening
the flange isolation. Both the type F and E gaskets are available in similar materials (phenolic,
neoprene, or high temperature phenolics such as G-10 glass epoxy) and have a standard
thickness of 1/8”. Type D gaskets are designed specifically to fit into the ring groove of a FIK D
ring type joint flange. Type D gaskets can be fabricated from a medium weave, fabric reinforced
phenolic resin (CE phenolic, G-10 glass epoxy, or high temperature G-3 glass phenolic) and can
be either of oval or octagonal cross-section.

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Type O gaskets for FIK O kits have a sealing element on each side of the gasket and are available
in both type E and F gaskets. Sealing elements can be nitrile, Viton or PTFE with gaskets made of
phenolic and G-10 glass epoxy and high temperature G-3 glass phenolic materials.

The specified gasket material is a function of the temperature of operation, corrosiveness of the
fluid and pressure of the pipeline. For example, neoprene faced phenolic gaskets have a
maximum operating temperature of 174°F while G-10 glass epoxy gaskets have a maximum
temperature of operation of 285°F.

For aggressive environments, specialty gaskets should be specified. For example, GPT Industries
offers a variety of specialty gaskets for specific types of environments. A VCS-ID Type F gasket
has a 316 stainless steel core retainer laminated on both sides with a G-10 fiberglass reinforced
laminate containing a patented, mechanically interlocking PTFE sealing element, which can
accommodate either flat, raised or ring joint face flanges. The inclusion of patented overlapping
and offsetting seal grooves into the gasket can create a chemically compatible barrier which
ensures only PTFE comes in contact with the aggressive fluid in the pipeline. The Evolution®
gasket, for example, is fully encapsulated and allows the gasket to be hydrotested and kept in
the pipeline with virtually no loss of isolation properties for ring type joints. The proprietary
coating is extremely abrasion, impact and chemically resistant to H2S, steam, CO and CO2 and is
rated 500°F when used with mica sleeves and washers.

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Isolating sleeves are typically made from high density polyethylene, NEMA grade phenolic, G10
glass epoxy or mylar. Material selection is based on temperature of operation for the pipeline.
High density polyethylene has a maximum operating temperature of 105°F, NEMA grade
phenolic of 225°F, G-10 glass epoxy of 285°F and mylar 300°F. Other high-temperature or
specialty materials are also available.

There are, however, downsides to using high density polyethylene isolating sleeves. Namely,
they are very unlikely to be able to hold up to the stresses imposed by a pipeline, which makes
them very likely to crack.

Materials Selection Considerations

Once the decision has been made as to the type of joint to use, materials of construction must be
specified.

Operating conditions of temperature, corrosivity of the fluid/gas in the pipeline, corrosivity of the
soil for a buried pipeline and pressure are critical parameters for selecting the gasket, sleeve and
isolating washer materials for an FIK. With increasing temperature high density polyethylene,
NEMA grade phenolic, G10 glass epoxy or mylar can be specified. Glass reinforced epoxy
gaskets are not inherently fire safe and should not be used with flammable gasses. Another
critical parameter is the dielectric strength or dielectric breakdown strength of the isolation
components, which is the maximum electrical potential that a material can resist before the
electrical current breaks through the material and is then no longer an insulator. Such electrical
breakthroughs can come from stray current.

Stray current flows through paths that are not the intended circuit can result in corrosion at a
specific endpoint. The isolation components must be sufficiently insulating to prevent such
electrical breakdown from stray currents. Water absorption by the insulating components can
assist the electrical breakthrough and should be as low as is possible. Although epoxy has low
water absorption, the incorporation of glass fibers greatly enhances the water absorption,
particularly during hydrostatic testing. There are new fully encapsulating isolation gaskets on
the market today that have excellent high temperature properties, have excellent compatibility
with process fluids and gasses and are fire safe. These new materials for FIKs allow them to

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The exact selection of isolation components should be done in consultation with the FIK supplier.
It should be noted that the physical properties of the lowest-rated component are the weakest
link and thus are the minimum physical properties of the entire combination. Note that not all
generic plastic components are fabricated from the same grade of material. Material certification
should be required and examined in detail prior to any installation. Replacement of an FIK should
be with in-kind materials (as verified by material certification tests) as this can be a source of
failure if alternative or lower quality materials are used.

Installation
Installing an FIK is fairly straightforward, as noted in ASME PCC-1 Guidelines for Pressure
Boundary Bolted Flange Joint Assembly. Before anything else, the kit should be examined to
confirm all parts are present and inspected to make sure that all parts are clean and defect-free.
Then, take the following steps:

1. Inspect the flange surfaces to be joined for debris and defects such as warpage, radial
scratches or hit marks. Remove any previously installed gaskets gently without scratching the
flange face. A plastic scraper can assist in removal of a previously installed gasket without
scratching the flange face; a screwdriver or steel scraper should not be used in order not to
scratch or damage the flange face. Any defective components must be replaced. A good
practice is to replace used gaskets, washers and sleeves with in-kind and not to re-install the
used ones back in the pipeline.
2. Arrange the flanges so the bolt holes coaxially align with a minimum gap of about ¼ to 3/8”
to prevent damage to the seal. Metal rods can assist in aligning the bolt holes. The gasket is
to be carefully placed between the flange faces. Depending on the orientation of the gasket
the use of untightened bottom bolts can assist in holding the gasket in place during further
assembly and assisting in centering the gasket.
3. Apply non-metallic bolt lubricant to the bolt and nut threads, to the face of the nut to be
tightened, and to the insulation washer and sleeve. Apply a nut to one end of the stud bolt,
slide the steel backing washer over the bolt, slide the insulating washer over the bolt and
then install the sleeve on the bolt. Insert the bolts with sleeves into the bolt holes by hand
and do not force them taking care to not damage the sleeves. Overhang of sleeve should be
per the manufacturer’s specification since too much extension can damage the sleeve and too
short cannot provide sufficient isolation. Non-metallic washers must be on the flange side
and then the metallic washer in order to maintain electrical isolation. Hand tighten the bolts
until the flange meets the gasket.

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4. Tighten the bolts with a torque wrench in accordance with the kit manufacturer’s
recommended torque. Good practice is to tighten each nut to initially 30%, 60% and then
100% of the recommended torque and to tighten in a star or cross-pattern as shown below to
properly align the flange. Numbering the bolts makes it easier to perform the star tightening
pattern for large diameter pipes. To make surethat all bolts re properly tightened, verify by
checking each bolt in a clockwise direction. Overtightening the bolts can cause damage to the
isolation gasket and sleeves with potential future loss of ability to provide adequate isolation
and leading to a loss of corrosion protection. Proper installation of the FIK is to be verified by
conducting isolation testing using an RF/IT meter per NACE RP0286 for every bolt to flange,
flange to flange and gasket to flange. Ring type joints end to be more difficult to install and
may require skilled personnel.

Order of tightening

Comparison Between Monolithic Isolation Joints and Flange Isolation Joints

As noted, pipelines carrying hazardous fluids/gasses and whether buried, above ground or
underwater, require protection against corrosion from air, water, corrosive fluids and electrical
currents caused by DC stray currents and lightning.

Flange isolation and monolithic isolation joints are two of the most widely used approaches as a
part of an integrated corrosion protection system for preventing electrochemical reactions from
occurring in a pipeline between two metals by breaking the metal path from traveling beyond the
area protected by the cathodic protection system.

In the past, availability of MIJs has limited their being specified but this is no longer the situation.

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Pipeline operators now must balance the higher initial cost of the MIJ versus their life cycle and
lack of required maintenance. MIJs usually have a higher dielectric strength than FIK. For those
reasons, buried and underwater pipelines tend to have MIJs while those above ground tend to be
FIK. FIKs also tend to be employed more between dissimilar metal piping. However, each has its
advantages. An FIK can be used in higher temperature applications depending on the materials
specified. Installation of an MIJ requires welding the joint into the pipeline by an experienced
welder; while, for a FIK, a properly trained individual can assemble the joint in a relatively short
period of time. However, care must be exercised in cleaning the flange face, centering the seal
and gasket, properly installing the sleeves and washers, applying the requisite torque to the
bolts so as not to crush the gasket and testing for electrical isolation. For the assembled FIK,
RF/IT testing should be conducted to confirm proper installation and isolation. Nondestructive
testing of the weld joints connecting the MIJ to the pipeline would be required for the MIJ. If a
post-weld heat treatment is required between the MIJ and the pipe, special precautions must be
taken to keep the temperature at the joint below 212°F. If buried below ground, the isolation joint
must be protected by properly being coated or wrapped from soil degradation/attack such as by
microorganisms. MIJs are designed to be at least as strong as the pipeline and are more resistant
to high mechanical and thermal stresses than an equivalent FIK. A FIK is not earthquake
resistant. A FIK can be disassembled for pipeline maintenance; when disassembled care must be
exercised so as not to damage any of the components and replace all with exact in-kind
components. The gasket for a FIK must be properly sized or there can be leakage or issues with a
pig getting stuck.

Table 3 compares the advantages and disadvantages of MIJs and FIKs. Consultation with the
supplier is highly recommended to obtain the required isolation joint for a specific environment of
service.

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 Table 3 Comparison between MIJs and FIKs

Case Learnings

Isolation joints have been successfully used by pipeline operators combined with cathodic
protection for many years to prevent catastrophic corrosion failures. Reports published in the
technical literature of successful operation of isolation joints are rarely described. However,
1
Weaver et al details best practices for cathodic protection for a buried pipeline where the
required isolation is primarily provided by MIJs.

Instead, reported leaks associated with isolation joints in pipelines can provide lessons learned
and how to improve and make more robust the selection and application of isolation joints.
Below are some recent published reports with lessons learned and best practices for improving
the selection, design and maintenance of isolation joints.

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 2
Keldsen reports that many of the issues associated with flange isolation joints are the result of
substitution of alternative materials than those originally specified or installed. The vast majority
of these alternate materials have inferior properties and do not meet the requisite design
specifications. In some instances, the defects should have been identified by field personnel; but
because of inadequate training of component inspection for installing the FIK, the FIK had a
premature failure. Reassembly of an FIK after maintenance requires diligence to ensure that all
correct electrically isolating components are installed. To prevent such issues, ordering and
installing FIKs from highly reputable manufacturers is critical for successful long-term operations.
In addition, many pipeline operators do not fully document the materials of the FIK initially used;
and thus, may not reorder a suitable replacement nor document the materials from the
replacement FIK for future replacement. Installation date and expected longevity should also be
included in the documentation.

Although glass reinforced epoxy gaskets have been widely and successfully used, they are prone
3
under certain conditions to leak because of permeation through the gasket. GPT has designed a
proprietary, highly electrically isolating coating encapsulated metal core, which has tighter seal
capabilities and thus eliminates the potential permeation.
Additionally, this type of gasket can provide fire safe operation, higher operating temperature,
tight sealing and greater chemical resistance. At the 2014 NACE meeting, Doering et al4
reported on the inadequacies of MIJs for severe service conditions of high temperature, high
pressure, sour gas service and lack of adequate quality control by some manufacturers. In
particular, they focused on materials selection, materials verification and documentation, and
qualification processes. The authors commented tht FIKs have “less robust designs have a long
history of failure in Chevron and in the industry. Chevron only accepts isolation gaskets from one
manufacturer for this reason and specifies coated metallic washers to ensure fire safety.”

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 5
At the 2017 NACE meeting, Monica et al responded with specific recommendations to address
the issues raised. Since MIJs are sealed systems, identification and inspection of the individual
components is not possible by the pipeline operator, where the inclusion of sub-standard
components can lead to pipeline leaks and ruptures. To alleviate this issue, the authors
recommended and have instituted at GPT to establish a contractual requirement that all MIJs and
their components be individually tested and not batch tested, which at the time individual MIJ
testing was not an industry practice by many MIJ suppliers. This requirement included:

Testing.
Materials traceability
Materials capability
Supplier auditing.
Weld certification.

The paper further demonstrated that generic materials, such as phenolics, glass reinforced epoxy
or PTFE materials, are not all the same and can have varying properties that impact their
performance. Thus, material specifications and certifications are critical for individual components
and should be required by all pipeline operators. The paper provides a suggested MIJ supplier
assessment survey as part of a supplier audit process that can ensure the supplied MIJ will
provide robust service in the pipeline. This approach can also be implemented for FIKs so that
materials verification and qualification for isolation gaskets, sleeves and washers meet the
requisite materials specifications.

AC interference for a pipeline can overwhelm the isolation joint and potentially result in corrosion
of the metallurgy. AC can come for buried pipelines from overhead high voltage transmission
lines or from lightning strikes for above ground pipelines. Over voltage protection devices
connected across the isolation joint are designed to mitigate this failure mode and protect the
isolation joint. Failure can still occur if the AC interference is too great. An initial survey for
determining localized AC hot spots can be useful. Regularly inspecting such isolation joints is not
always practical; remote monitoring devices and alarm notification are suggested6 for continuous
evaluation of pipeline integrity.

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Pimenta and Luqman7 reported that a discharge was a result of corrosion from current leakage
across the protected and unprotected sides of the MIJ. The isolation length used was incorrect
and that models for these calculations require further studies to eliminate such issues.
Contributing factors to the discharge included bending stresses from improper installation and
incorrect selection of materials for the requisite operation. These papers demonstrate the
continuous improvement of the isolation joints based on field/service operations. Design and
operation of a pipeline is quite complex but lessons learned leads to improved quality and
durability of isolation joints resulting in increased operational reliability.

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 Conclusions

This paper is meant as a resource for pipeline owners, managers and staff that want a greater
understanding of strategies for preventing pipeline corrosion and how flange isolation kits and
monolithic isolation joints can further improve corrosion protection and thus minimize leaks and
ruptures from corrosion.

Isolation joints eliminate metal-to-metal contact, halt static current flowing through the entire
pipeline and aid cathodic protection of the piping system. MIJs and FIKs are integral and critical
components for an effective corrosion mitigation system for pipelines. Combining them with
cathodic protection and coatings results in a robust system for minimizing corrosion issues.
Selection of a FIK or MIJ for a specific application should be based on operational, installation and
maintenance requirements parameters.

Isolation joints can:

1. Eliminate metal-to-metal contact
2. Prevent static current corrosion
3. Aid in the cathodic protection of the piping system by segmenting the pipeline

Construction of isolation joints with high quality materials that have a high dielectric constant,
low water absorption and high temperature property compatibility is required. Many pipeline
isolation joint failures are the result of the installation of sub-par quality materials, improper
installation or selection of isolation components that are not suitable or compatible with the
process conditions. Critical parameters for consideration are fluid/gas temperature, pressure and
corrosiveness, and external soil conditions. Documentation of the materials of construction for the
FIKs during initial installation and reviewing that documentation prior to replacement can prevent
potential leaks from installing inferior materials. A supplier audit is extremely useful for obtaining
an isolation joint suitable for the requisite application. The audit should include examination of
code compliance of the isolation joint and testing of individually installed components per
standard methods (such as ASTM). For MIJs, each isolation joint should be tested for electrical
insulation, for leakage by hydrostatic testing and by non-destructive testing for weld quality.
Manufacturers of MIJs and FIKs continue to improve their longevity and functionality for ever
more aggressive environments.

Further information can be obtained at gptindustries.com

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 References

1. JWeaver, LCornish, SBell, and JGehring, “Cathodic Protection Best Practices Employed with
the 150 Mile TRWD/DWUIPL Pipeline”, Pipelines 2020 (2020) 45-54
2. JTKeldsen, “Causes of Flange Isolation Gasket, Sleeve and Washer Failure,” Materials
Performance, 50, (August 2011) 32-34
3. THurley and MBender, “New Design/Material Solution for Isolating Pipelines with Chemical
and Permeation Issues,” NACE Paper 2018-11559 (2018)
4. KDoering, SMishael, RERettew, and CButerbaugh, “Monolithic Isolation Joints: A Possible
Weak Link in Pipeline Integrity,” NACE Paper 2014-3989 (2014)
5. MMonica, THurley, JStephenson, and WTroutman, “In Defense of the Monolithic Isolation
Joint,” NACE Paper 2017-8993 (2017)
6. JHilleary, JDewitt, and LKrissa, “Monitoring DC Decoupling Devices at Isolation Flanges for
Compliance and Pipeline Integrity”, NACE Paper 2015-6077 (2015)
7. GPimenta and ALuqman, “Monolithic Isolation Joint Failures,” Materials Performance, 58(6)
(June 2019) 28-31

Relevant Standards

NACE RP0286 Standard Recommended Practice Electrical Isolation

of Cathodically Protected Pipelines

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B31.3 Process Piping Guide,

ASME B31.4 Pipeline Transportation Systems for Liquids and Slurries

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B31.8 Gas Transmission and Distribution Piping

ASME VIII Division 1 Rules for Construction of Pressure Vessels

ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly

U.S. Code of Federal Regulations (CFR) Title 49. “Requirements for Corrosion Control.” Part 192

U.S. Code of Federal Regulations (CFR) Title 49. “Corrosion Control.” Part 195

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