Flange Insulation Sets

Insulation sets are used to limit corrosion in pipeline systems. Where dissimilar metals are present, the sets remove the possibility of the system acting as a galvanic cell and reduce the risk of galvanic corrosion of the pipe work. Insulation sets are also used to isolate cathodically protected piping systems where they prevent the flow of electro-static charge.

Each flange insulation set comprises one central flat or oval section gasket, plus one insulation sleeve , two insulating and two stainless steel washers per bolt. The sets are individually packed and clearly labelled with the flange rating, size, type and material combination.

Key function of Insulating gaskets

Used to electrically isolate sections of pipe work
Designed to minimise electrochemical erosion
Comprising materials with high dielectric strength
Manufactured to suit flanged joints to ASME, BS, DIN and customer designs.

Typical Flange Insulation Set components

Standard Sleeve & Washer Materials in the Set are:
• Mylar Sleeves
• G10 Insulation Washers
• Stainless Steel Metal Washers
• Others on request

The Types of Insulation Gaskets

Style E - Full face gasket insulating set assembly

Suitable for flat and raised face flanges. This style minimises the ingress of conductive foreign matter and reduces the risk of bridging. Typically used on oil and hydrocarbons where flange insulation is a requirement. Manufactured from materials with high dielectric strength to ensure minimum electrical contact between flanges.

Style F – Inside bolt locating gaskets insulating set assembly

Utilises a RF gasket which centrally locates within the bolts. Typically used on oil and hydrocarbons where flange insulation is a requirement. Manufactured from materials with high dielectric strength to ensure minimum electrical contact between flanges.

Style D – Ring Joint Gasket

Technical Specifications for Klinger manufactured Insulating gaskets sets

Component	1	2	3	4	5	6
Dielectric Strength1 kV/mm	19.8	31.5	157.5	21.3	3.6*	16.7*
Water Absorption %	1.6	0.05	0.8	10.6	0.5	0.5
Max. Operating Temp. °C	107	150	145	400	260	260

Test according to ASTM D149 in transformer oil. To convert from kV/mm to V/mil multiply by 25.4. * Test according to ASTM D149 in air.
Recommended maximum temperature in air for electrical isolation purposes.

Component Material

Type E and F Flat Gasket 3.0mm thick neoprene faced phenolic
Insulating Washer 3.0 mm thick G10
Insulating Sleeve Mylar
Type E and F Flat Gasket 3.0mm thick KLINGERSIL® C-4430. Rated fire safe
Type E and F Flat Gasket 3.0mm thick KLINGER®top-chem 2000. Rated fire safe
Type E and F Flat Gasket 3.0mm thick KLINGER®top-chem 2003

Service Recommendations

The choice of insulation gasket for a given duty is dependent on the application conditions under which they will be operating. In addition to the temperature limitations, selection of the gasket must take into account the intended flange pressure class. The table below presents Klinger recommendations for safe sealing of ANSI flanges requiring insulating properties. The recommendations are based on both product knowledge and feedback from the field. For applications with specific service conditions, please refer to Klinger / PT Loka Manggala for a recommendation

Gasket recommendations for ANSI B16.5 Raised Face Flange Class

√ -recommended ; Χ -not recommended

Pressure Class Rating ANSI B16.5 Raised Face

Gasket	150	300	600	900	1500	2500
Topchem 2003	√	√	×	×	×	×
C-4430	√	√	√^∗	×	×	×
Topchem 2000	√	√	√^∗	×	×	×
Style LPS	√	√	√	√^∗	√^∗	×
HPS-High Pressure Spring Energised PTFE	√	√	√	√	√	√

Properties:

	Component	Dielectric Strength (Kv/mm)	Water Absorption (%)	Maximum Temperature (°C)
Klingersil C-4430	Gasket	21.3	10.6	400
Klinger Topchem 2000	Gasket	3.6	0.5	260
Klinger Topchem 2003	Gasket	16.7	0.5	260
G10	Gasket, Sleeve, Washer	24.1-31.5	0.1-max.	150
G11	Gasket, Sleeve, Washer	24.0	0.1 -max.	200
Mylar	Sleeve	157.5	0.8	145
Phenolic	Sleeve	5.5	1.0	107
Reinforced Phenolic	Washer	7.8	1.0	107

Note: The above values are based upon limited test data. Whilst every effort is made to ensure the information in this data sheet is accurate, it must be stressed that it is the users responsibility to ensure suitability for the intended end use. The values quoted above may be subject to modification at a later date.

Flange Protection

It is recommended that a Klinger Flange Band Protector is also used to cover the outside of the flange to prevent the ingress of conductive matter.

Klinger Limited guarantees the quality, materials and workmanship of all its products either manufactured or distributed, but cannot be held responsible for the manner in which they are used, fitted or stored

For sales and technical advice, please contact:

Klinger / PT Loka Manggala: lokamanggala@cbn.net.id