Schuck Group SHD User manual

SCHUCK INSTALLATION/OPERATION MANUAL
Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
Translation of the original German Operation Manual
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Codeword: STANDARD
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Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Introduction
Introduction
This manual is written for installation, operating, maintenance and supervisory
personnel.
This manual also describes components and auxiliary units that are not included
or are only partially included in the scope of supply.
The manual must be read, understood and observed by the user. We emphasize
that Franz Schuck GmbH assumes no liability for damage or malfunctions arising
from non-compliance with this manual.
With regard to the illustrations and information in this manual, we reserve the right
to make technical modifications.
Copyright
The copyright for this manual remains with Franz Schuck GmbH.
The instructions and drawings contained herein may not be reproduced or dissem-
inated either fully or in part, nor used for competitive purposes or communicated
to other parties without authorization.
Contact address
Franz Schuck GmbH
Daimlerstraße 5 – 7
89555 Steinheim
GERMANY
Phone [phone]
Fax [phone]
[email protected]
www.schuck-group.com

I
Table of Contents
Table of Contents
Chapter 1 1-1Preliminary remarks
1.1 1-1Legal notes
1.2 1-1Application range
Chapter 2 2-1Safety
2.1 2-1Fundamental safety instructions
2.1.1 2-1General
2.1.2 2-2Intended use
2.1.3 2-3Organizational measures
2.1.3.1 2-3Special hazard points
2.1.3.2 2-4Workplace and personal protective gear
Chapter 3 3-1Description
3.1 3-1Types
3.2 3-2Task, function and components
3.3 3-4Designation
3.4 3-4Accessories and connections
Chapter 4 4-1Installation
4.1 4-3Preparing the installation
4.1.1 4-3As-delivered condition
4.1.2 4-4Inspection
4.1.3 4-4Storage
4.2 4-5Installation
4.2.1 4-5General installation instructions
4.2.2 4-6Installation
4.2.3 4-7Function test
Chapter 5 5-1Operation
Chapter 6 6-1Maintenance
6.1 6-1Faults and troubleshooting
6.2 6-2Repairs

II
Table of Contents
Chapter 7 7-1Appendix
7.1 7-1Tightening sequence for flange bolts
7.2 7-2Conversion factors
7.3 7-3Calculation formula to determine the carbon equivalent (CEV)
7.3.1 7-3Calculation formula (standard)
7.3.2 7-3Calculation formula for steels with different consistencies
7.4 7-4Maximum permissible torsional moments for insulating joints with socket screw
threads

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
1-1
Codeword: STANDARD
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Preliminary remarks
1 Preliminary remarks
CAUTION
Danger of consequential damage due to incorrect operation, maintenance
and/or handling!
We explicitly emphasize that we assume no liability for damage or malfunctions
arising from non-compliance with this manual.
ÖTherefore it is important to comply with all instructions in this manual!
This manual is to provide technicians and users with the necessary information
for assembly and adjustment work and to help in performing work quickly and
correctly.
For your own safety, read this manual carefully and pay particular attention to the
highlighted tips. In any case, keep this manual to hand.
Pay special attention to all safety instructions in this manual. You will find the
safety instructions in Chapter 2, in the introductions to chapters and before prac-
tical instructions. The General Terms and Conditions of the company apply exclu-
sively to all deliveries and performances made by Franz Schuck GmbH, including
any future transactions.
1.1 Legal notes
The component may only be installed by skilled staff.
Please check parts upon receipt for any possible damage that may have occurred
during transport. Only undamaged parts may be fitted or used.
No warranty can be claimed if maintenance work is neglected or carried out incor-
rectly. Only original spare parts guarantee quality, reliability and exchangeability.
Any modification(s) of the component are in general prohibited by Franz Schuck
GmbH. The manufacturer guarantee becomes void if this prohibition is not com-
plied with!
1.2 Application range
This operation manual applies to the Franz Schuck GmbH product described in this
manual.
The appropriate operation manuals for optional accessories must also be ob-
served.
These operation manuals are included in the overall documentation if the acces-
sories belong to the scope of supply from Franz Schuck GmbH.

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Safety
2 Safety
CAUTION
Dangers to the health and safety of operating and maintenance staff as well as
to the functioning capacity of the component. Dangers to the environment due
to escaping gaseous or liquid media.
Danger to life due to escaping steam or hot water!
Non-compliance with these instructions jeopardizes the obligation by Franz
Schuck GmbH to follow through on the warranty/guarantee.
ÖThe instructions in the “Safety” Chapter must be unconditionally observed!
2.1 Fundamental safety instructions
2.1.1 General
Modifications on the component which could affect safety may not be carried out
without written permission from the manufacturer.
The guarantee becomes void if this prohibition is not complied with!
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• This product has been manufactured according to the recognized rules of
technology and according to internal Schuck quality standards; the product is
shipped from the factory in a perfect technical condition
• Nevertheless, components can cause hazards to people, material goods and
the environment if installation personnel use them improperly or in a manner
that is contrary to their intended use
• Any person dealing with assembly, commissioning or maintenance of the com-
ponent must have read and understand this entire manual, and must be able
to prove they possess professional qualifications for implementing the work
• Please observe the valid accident prevention regulations when installing the
component
• Suitable protective gear must be worn when carrying out the works
• The manual must be kept safe and accessible at all times at the place where
the component is in use
• If malfunctions occur, take appropriate measures immediately and notify Franz
Schuck GmbH
• Work on components (such as inspection work, servicing and/or maintenance
work) may only be carried out in a depressurized state
• Components must be effectively covered and/or protected when work is being
carried out that could lead to contamination of or damage to the component,
the assembled parts and/or the anti-corrosion protection

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Safety / Fundamental safety instructions
2.1.2 Intended use
The component supplied is designed exclusively to block completely the metal
conductivity in a pipeline or a cathodic corrosion protection system.
It is not designed to absorb occurring forces and torques. If this is required, this
must be specified in the order or the enclosed specification.
The component can be designed for gas and liquid media.
Any other media and/or applications outside the permissible pressure and temper-
ature range can lead to damage and/or leaks.
Intended use includes observing the instructions in this operating manual and ad-
hering to the operating conditions on the component, the final inspection certifica-
tion and drawings, as well as observing the locally applicable accident prevention
guidelines and regulations for protecting the environment.
Any operating conditions or applications which differ from those prescribed are
only valid with the agreement of Franz Schuck GmbH!
CAUTION
ÖObserve the following specifics regarding operation with oxygen.
• Oxygen pressure surges during operation are not permissible
• Maximum permissible pressure increase = 20 bar / min. (0.33 bar / s)
• Maximum permissible flow speed at pressures ≤40 bar: 25 m/s
• Maximum permissible flow speed at pressures >40 bar: 8 m/s
• The oxygen flow must be free from inflammable particles
• The influence of electrical discharge on the insulating sealing ring must
be eliminated
• Keep insulating joint free from oil and grease!
• Installation must be completely free of grease
• The insulating joint must be free of water and cleaning agent residue

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
2-3
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
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Safety / Fundamental safety instructions
2.1.3 Organizational measures
2.1.3.1 Special hazard points
There is no immediate danger from a component that is installed according to
instructions.
Life hazard in the case of escaping steam or hot water!
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• Danger from escaping media
– depending on the working medium, fire or explosion hazards can arise from
electrical contact, naked flames, light and/or smoking
– there is a risk of poisoning, chemical burns, scolding and environmental
pollution
– hazardous materials must be collected or sucked up, if necessary, and dis-
posed of properly

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Codeword: STANDARD
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Safety / Fundamental safety instructions
2.1.3.2 Workplace and personal protective gear
Sufficient space is required for carrying out assembly and maintenance work
safely. The operator must ensure that the workplace is clean and clearly arranged.
If media (including residues) can escape in case the component experiences op-
erational faults or malfunctions, then the endangered persons must use suitable
personal protective gear, as far as this is necessary.
Only use components in a technically undamaged condition; use them according
to specifications in a safety and risk conscious manner while complying with the
operating manual! Remedy faults in particular that could impair safety (or have
them remedied)!
The operating manual must be supplemented by instructions which take into ac-
count supervisory and reporting duties with regard to work related particularities,
e. g. in respect of how work is organized, working procedures and the personnel
employed.
Staff commissioned to work on a component must have read the chapter on safety
in this operating manual before starting work. Staff must already be aware of
potential hazard sources when working to be in a position to react quickly and
correctly. This applies in particular to staff who are only employed occasionally to
work on a component, e.g. when setting up or servicing.
Observe all safety and hazard instructions for the equipment/the component!
Make sure all safety and hazard signs are complete and legible!
No modifications, attachments or conversions which could impair safety may be
implemented without authorization from Franz Schuck GmbH!
Adhere to the prescribed deadlines, or the deadlines stated in the manual, for re-
curring tests/inspections!
Make sure the location or fire extinguishers is clearly indicated and operating in-
structions are available!
Make sure to observe the fire alarm and fire fighting instructions!

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
3-1
Codeword: STANDARD
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Description
3 Description
3.1 Types
Type Connection
SHD, SHD-K with welded connection on both sides
SHDF with flanged connection on both sides
SHDFS on one side with welded connection
and on the other side with flange
connection
SHM two-sided socket screw thread
Tab. 3-1 Characteristics

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Codeword: STANDARD
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Description / Task, function and components
3.2 Task, function and components
The insulating joint is a fully welded construction (monobloc).
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Task
Insulating joints are used for interrupting the metal conductivity of a pipeline or a
cathodic corrosion protection system.
Function
In the event of an excess voltage (higher than 5 kV), it is deviated via the annular
spark gap. The insulating joint remains fully functional.
Components
1910 11
6
457
3
28
13 12
320nn001
Fig. 3-1 System overview insulating joint SHD
1Outer coating
2Collar 1
3Seal ring
4Insulation ring
5Annular space
6Annular spark gap
7Forged collar ring
8Collar 2
9Filling compound
10 Pipe connecting socket
11 Inner coating (optional)
12 Insulation ring
13 Pipe connecting socket

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
3-3
Codeword: STANDARD
Created with: TeXML v.schuck-latex-170131
Author: Franz Schuck GmbH Editor: bitplant.de GmbH
As of: 2017-06-26 (Release 1.6) Revision: –
Description / Task, function and components
13 12
8910
6
457
32
1
11
320nn002
Fig. 3-2 System overview insulating joint SHDF
1Outer coating
2Collar 1
3Seal ring
4Insulation ring
5Annular space
6Annular spark gap
7Forged collar ring
8Collar 2
9Filling compound
10 Flange
11 Inner coating (optional)
12 Insulation ring
13 Flange
8910
6
457
3
11
13 12
2
1
320nn003
Fig. 3-3 System overview insulating joint SHDFS
1Outer coating
2Collar 1
3Seal ring
4Insulation ring
5Annular space
6Annular spark gap
7Forged collar ring
8Collar 2
9Filling compound
10 Pipe connecting socket
11 Inner coating (optional)
12 Insulation ring
13 Flange

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
3-4
Codeword: STANDARD
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Description / Designation
9
8
10
6
47
3
11 12
2
1
SHM
5
10
11
320nn004
Fig. 3-4 System overview insulating joint SHM
1Outer coating
2Collar 1
3Seal ring
4Insulation ring
5Annular space
6Annular spark gap
7Forged collar ring
8Filling compound
9Collar 2
10 Wrench size
11 Socket screw thread*
12 Insulation ring
* also available with additional male connector Îtype SHM-EO
3.3 Designation
The stamped name plate contains the following data:
• Schuck logo
• Type
• Nominal pressure
• Material
• Ident. no.
• Part no.
Additional identifiers must be specified in the order or the specification respec-
tively.
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3.4 Accessories and connections
Depending on the order, the insulating joint can be equipped with optional acces-
sories or with interfaces for other accessories:
• Welded-on lugs for external spark gap
• External spark gap
• Connections for measuring instruments or similar

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Codeword: STANDARD
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Installation
4 Installation
For questions regarding installation, please contact:
Franz Schuck GmbH
Daimlerstraße 5 – 7
89555 Steinheim
GERMANY
Phone [phone]
Fax [phone]
[email protected]
www.schuck-group.com
DANGER
Dangers to the health and safety of operating and main-
tenance staff as well as to the functioning capacity of the
component! Dangers to the environment due to escaping
gaseous or liquid media!
Risk of bursting components and danger caused by the
operating medium due to incorrect assembly/disassem-
bly!
ÖComply with all instructions specified in this manual!
DANGER
Danger of electric shock!
ÖDo not connect the system to power before the earth
resistance and the earthing connection has been
tested, examined and approved by the customer.
DANGER
Risk of injury from bursting components/system parts!
If the permissible limit values are exceeded, the compo-
nent/system can be destroyed, and as a consequence of
this persons can be injured or killed!
ÖAlways operate components/system parts within the
permissible limit values!

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Codeword: STANDARD
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Installation
CAUTION
Risk of shorter service life of the component due to incorrect assembly and use!
ÖRemove any rust or deposits from the weld-on ends before welding.
ÖEnsure that the component is stress-free during assembly (no flexion, tor-
sion, traction or stress).
ÖObserve the thermal load limits of the seals and the lining of the component
if applicable.
ÖProtect internal lining and coating from damage during welding works (e.
g. from welding spatters).
ÖMake sure that no override voltages can occur during the welding process.
CAUTION
Danger of hardness increase of the steel when welding without pre-heating the
weld junction at temperatures exceeding 80 °C!
ÖPre-heat the weld-on ends depending on the carbon equivalent (CEV) before
starting the welding process.
ÖObserve the notes on CEV (ÎPage 7-3, Chapter 7.3).
ÖMake sure to monitor the temperature when pre-heating and welding!
Suitable measures (such as cooling, extending the weld-on ends without
coating, dismantling, etc.) must be taken to avoid elevated temperatures in
areas with coated surfaces.
Temperatures of up to 100 °C are permissible for a short time.

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Installation / Preparing the installation
4.1 Preparing the installation
4.1.1 As-delivered condition
DANGER
Life hazard from dropped loads or shifting of loads!
Risk of injury and/or material damage due to incorrect
installation or inappropriate equipment and devices for
lifting or moving the load.
ÖLoad-carrying equipment, lifting devices and indus-
trial trucks must comply with the current regulations!
ÖIt is forbidden to stay under suspended loads.
ÖMake sure to observe the country-specific regulations
during transport.
If no other contractual agreements have been made, the components are supplied
for transport under the following conditions:
• weld-on ends are coated with an anti-corrosive product
• the components are packed on wooden pallets, lattice boxes or boxes
Procedure
1. Only use the original packaging for transporting the component to its place of
installation.
The component can be damaged by incorrect handling.
2. Only use lifting devices that are appropriate to the weight being moved.
3. Use appropriate protective materials when using steel cables or chains in order
to protect the outer coating.
4. Ensure the load does not tip sideways.

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Installation / Preparing the installation
4.1.2 Inspection
Procedure
1. Check the delivery notes to make sure that the delivery is complete.
2. If there are any discrepancies, contact Franz Schuck GmbH immediately.
3. Check the delivery immediately on receipt for damage incurred during trans-
port.
In the event of damage occurring, observe the stipulations of the insurance
company which, among other things, prescribe that evidence of damage is con-
firmed immediately by the forwarding agent.
4. If applicable, photograph damage to proof evidence.
4.1.3 Storage
Store the component in its original packaging.
Take suitable measures to protect the component against external influences, dirt
and moisture.

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Installation / Installation
4.2 Installation
CAUTION
Damage to the component in the case of mechanical overloading!
The component is not designed as fixed point/support of the pipeline.
ÖExtra support on the pipeline is required.
ÖIn the case of liquid media where deposits may accumulate in the insulation
ring area (e. g. oil, condensates, etc.), install the component in a tilted
position (≥30°).
4.2.1 General installation instructions
Prerequisite
• Check parts on receipt for any possible damage that may have occurred during
transport. Only flawless parts may be installed.
• The component may only be installed by skilled staff.
• Carefully remove the anti-corrosion protection on the weld-on ends using ap-
propriate means.
The insulating joint must be clean and dry on the inside.
Prior to installation, an electrical resistance test must be carried out using 500 V
direct current.
The resistance measured must not fall below 0.1 MΩ.
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• Prior to installation, check the pipelines for dirt and foreign particles, clean if
necessary
• Ensure that no dirt or foreign particles can get into pipeline or component dur-
ing installation
• Ensure that inner and outer coating are not damaged during installation
• Ensure that the component is installed into the pipeline stress-free. It is not
designed to absorb occurring forces and torques

Insulating joint SHD, SHDF, SHDFS, SHD-K, SHM
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Codeword: STANDARD
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Installation / Installation
4.2.2 Installation
Procedure
Insulating joint – version with weld ends
1. The insulating joint is installed in the same way as the ones in the pipeline that
is to be installed or welded.
2. In the case of insulating joints with both-sided weld-on ends, it is recom-
mended to install the forged collar ring facing towards the side that is to be
protected cathodically. In the case of insulating joints with one-sided internal
coating, the coated side must face towards the side that is to be protected
cathodically. The side facing towards the cathodic protection is marked with a
label.
3. In case the insulating joint must be cut to length for proper installation, it must
be ensured that the remaining distance of the respective welding seam be-
tween pipeline and insulating joint to the dielectric is generally at least 1x the
nominal diameter of the insulating joint.
4. The welding can either be carried out in vertical up position (PF) or vertical
down position (PG) by approved welders.
5. The selection of the welding technique and the electrodes depends on the ma-
terial of the insulating flange connection pipes and of the pipelines.
6. After checking the weld seams and the pipeline (pressure test), the weld seams
must be provided with an electrically insulating covering that complies with the
requirements of protective insulations.
7. Due to the spark gap integrated in place, an additional spark gap is not neces-
sary.
8. Following a final inspection of the pipeline, the insulating joint must be em-
bedded correctly, i. e. the back-fill material must not contain any sharp-edged
objects and it must be compressed properly.
Insulating joint – version with flanges
1. The flange seals and bolts must be suited for sealing strip shape, pressure,
temperature and medium.
2. The pipeline counter flanges must be aligned plane-parallel and concentrically.
3. Tighten the screw connections crosswise and evenly with the appropriate tight-
ening torque.

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Installation / Installation
Insulating joint – version with socket screw threads
1. When installing insulating joints with socket screw threads, the pipeline
counter pieces must be aligned concentrically.
2. An additional spark gap is not required due to the spark gap integrated here.
3. If male connectors are screwed in the socket screw threads by the customer,
it is essential to ensure that when screwing in the respective connector, the
insulating joint is fixed on the same side using a wrench with the appropriate
wrench size.
4. The maximum permissible torsional moments for insulating joints with socket
screw threads are specified in the annex (ÎPage 7-4, Chapter 7.4). Ensure
that these moments are not exceeded, both during installation and in installed
condition. This prevents potential twisting of the insulating joint.
For type SHM-EO with additional male connectors, the following issues must be
observed additionally:
1. When installing insulating joints with additional male connectors, the pipe rec-
ommendations of the connecting element manufacturer must be observed.
2. In addition, the manufacturer’s mounting instructions must be observed.
Tighten the male connectors with the tightening torque appropriate for this
application.
3. Pipes must be cut to length and deflashed carefully, minimum lengths for pipe
ends must be observed. Ensure that cap nuts can be screwed easily over the
entire thread length.
4. Every time a connection is undone, the cap nut must be tightened with the
same effort applied during initial installation. Once assembled, pipe connec-
tion and screwing element belong together.
5. Retightening and venting of pressurized connections is dangerous to life.
Electrode and autogenous gas welding techniques are possible during installation.
For autogenous gas welding the Franz Schuck GmbH recommends to cool the in-
sulating flange construction (e. g. by means of a damp cloth) to prevent the seal
and insulating material from damage if the temperature exceeds 80 °C.
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4.2.3 Function test
When welding is finished, a pressure test in the pipeline must be scheduled.