What are Insulating Gaskets?

Their Types, Components,

Applications, Installation (PDF)
whatispiping.com/flange-insulating-gasket-kits/

Anup Kumar Dey February 22, 2020

What is Flange Insulation Gasket Kit?

The most common problematic area for a Piping/Pipeline System design is flanges. So we
have to be doubly sure to seal it properly to prevent flange leakage. At the same time, It must
also be insulated cathodically so that stray currents which are known behind the undue
corrosion and eventual metallic breakdown be prevented. Insulating gasket sets or Flange
insulation kits play an important role in such cases.

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Table of Contents

What is Flange Insulation Gasket Kit?

Major Applications of Insulating Gasket Kit
Components of Flange Insulation Gasket Kit
Assembling of the flange insulation gasket kit components
Types of Flange Insulating Gaskets
Insulating gasket Material
Sleeves and Washers of Flange Insulation Gasket Kits
Flange Insulation Gasket Kit Installation procedure
Common Vendors for Insulating Gasket Kits
Information needed for Ordering Flange Insulating Kits

They are designed for electrically insulating the flanges.

They act as an insulator between dissimilar metallic flanges.
Also, they are used to isolate sections of pipework (dissimilar metals) electrically
in the cathodic protection systems; thus preventing the electrostatic charge flow
along the pipelines as they remove the possibility of galvanic cell system
creation.

Major Applications of Insulating Gasket Kit

Insulating gasket kits can be used in all such places where galvanic corrosion protection
and electrical insulation are needed. Common Application areas are piping/pipeline systems
with seawater environments, offshore installations, chemical installations, oil refinery
pipelines, etc.

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Components of Flange Insulation Gasket Kit
Each flange insulation Kit (Refer to Fig. 1) constitutes of

one central flat or oval section gasket,

one insulation sleeve per bolt and
two insulating steel washers per bolt and
two plated steel washers per bolt.

All these components are produced using special materials possessing chemical stability,
dielectric properties, and low water absorption so that the purpose is solved. The full sets are
packed individually and labeled clearly mentioning the flange size, rating, type, and material
combination. Insulation kits are generally available upto 24 inches, but custom-made higher
nominal sizes can be produced on the requirement.

Fig. 1: Components of Flange Insulating gasket

Kit

Assembling of the flange insulation gasket kit components

The polyethylene insulating sleeve and the mounting stud are the main components of the
insulating gasket kit. Contrary to the conventional nut and bolt system of flanged joints, the
insulation kit uses a stud with a washer and nut on each end of the flange joint. The
insulating sleeve is then inserted into the bolt holes using one insulator on each side of the
flange. So, Two insulators per bolt hole are inserted into the flange. Then the mounting stud
is inserted into the insulating sleeves until threads on each end of the stud are visible outside
of the flange. A flat steel washer is slid onto the stud at each end, and a nut is threaded onto
each end of the stud and tightened.

As a nut is tightened on each end of the stud, the flange insulation kit becomes much
stronger than the typical nut-and-bolt type connection. In the traditional manner of nut-bolt
tightening, all of the clamping force is applied to the single set of threads on the bolt while in
the case of a double-ended stud such as in a flange insulation kit, the clamping force is

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divided equally between the threads on each end of the stud as well as inside both nuts. The
stud is protected and insulated from any electric charge and corrosion. This creates a
flanged connection that will not corrode or fail due to a chemical reaction between two
dissimilar metals.

Types of Flange Insulating Gaskets

Four major types of gasket isolation kits are available in the market those are designated as
F, E, D, & O. Each type of flange kit fits flanges with a specific type of flange face (RF, FF,
RTJ).

F Type Gasket

Type F type gaskets are produced to fit the raised face flanges. The inside diameter of the
bolt-hole circle is made slightly smaller than the external diameter of the gasket which
assures automatic positioning of the gasket. To avoid the accumulation of foreign materials,
Special band protectors can be used for the joint assembly to strengthen the cathodic
isolation further. These are manufactured from 1/8″ thick fabric-based phenolic sheets either
without coating or a with a nitrile rubber coating on the two faces. Type F gaskets are also
available in non-asbestos fibers with high isolation capacity.

E Type gasket
In full-face type, Type “E” Gaskets, the outside diameter of the gasket matches the
external diameter of the flanges. So the gasket completely covers the whole flange surface.
There are produced with precision-located bolt holes and are easy to position in the center.
This design will prevent foreign material accumulation between the flange faces and thus
enhances the isolation properties of the kit. Type E flange insulation kits are available in
phenolic, neoprene-faced phenolic, and high-temperature materials.

D Type Gasket
Type “D” Gaskets are manufactured to fit into the ring groove of RTJ flanges (style R, RX,
and BX). They are available in medium weave reinforced phenolic and other materials are
sized to ANSI specifications available in a basic oval as well as an octagonal shape. This
type of gasket is known as an “API ring joint”.

O Type gasket
Type O Gaskets are extra special as they feature an additional sealing element on both
sides of the device, generally, PTFE, Nitrile, or Viton Rubber, and are available in both ring
and full-face designs (type E and F).

Insulating gasket Material

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 All materials should be selected to assure long-term effective sealing and electrical
insulation of the flanged joints.
To take advantage of the best characteristics, sometimes, gaskets are made with
combinations of materials.

Normal Gasket materials are G3, G7, Nitrile-Face, Plain Phenolic, G10, Neoprene-faced
Phenolic, Klinger, Teflon, Durlon, etc. Popular Sleeve materials are Phenolic, Mylar,
Polyethylene, Minlon, or Nomex. Common washer materials are Phenolic, Steel, G7,
G3, or G10 available as a single washer and sleeve kit, a one-piece washer kit, a
double washer kit, or a one-piece double washer kit (Minlon)

Sleeves and Washers of Flange Insulation Gasket Kits

One-piece sleeves and washers

One-piece sleeves and washers are available molded from acetal resin. They should
generally be used as single washer sets since they are molded to specific lengths and are in
many instances longer than the thickness of a single flange. They are available for bolt
diameters of ½” to 1-1/2″ (12.7 mm to 38.1 mm), and are limited to applications where the
flange temperature does not exceed +180^oF (+80^oC).

A special feature is a washer centering ring that positions the steel washer on the unit
properly to avoid uneven pressures on the washers.

Insulating Washers

Standard insulating washers are made of high-strength phenolic and provide tough, positive
insulation at temperatures of +3000F ( +1500C). They are available for bolt sizes from ½”
(12.7 mm) through 3 ½” (88.9 mm) and are made to fit over the insulating sleeves.
Fiberglass reinforced high temperature phenolic insulating washers are available on special
order in the same sizes as the standard insulating washers

Insulating Sleeves

Insulating sleeves are available in Mylar, polyethylene, phenolic, and Nomex. They are
through 3-1/2″ (88.9 mm) and are designed to fit easily over the flange bolts, and may be
used with standard-sized bolts and bolt holes even with some misalignment. Insulating
sleeves are used with separate insulating washers and have a standard wall thickness of
1/32″ (0.79 mm). They are available for standard American bolt sizes from ½” (12.7 mm) to 3
½” (88.9 mm), as well as metric bolt sizes from 12 mm and larger.

Steel Washers

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Steel washers are designed to fit over the insulating sleeve or retainer ring on the one-piece
sleeves and washers. The outside diameter is sized to fit within the bolt facing on ANSI
standard flanges. They are of 1/8″ (3.2 mm) thick plated hot-rolled steel. Pyrox insulating
sleeves and washers are also available.

Flange Insulation Gasket Kit Installation procedure

The Gasket ID (inside diameter) is normally made slightly smaller than the flange ID. While
installing ensure that the gasket is properly centered over the bore. It will prevent the build-
up of foreign material between the flange faces during pigging.

Single washer insulating sets are recommended for underground flanges. This should be
installed on the unprotected side of the flange, which will provide cathodic protection for the
studs as well as the nuts. For above-ground flanges, It is suggested to use Double washers
for ease in testing.

The use of alignment pins is always suggested which will ensure proper alignment of flanges
and gaskets. The size of each Pin shall be a minimum of 3/32″ (2.38 mm) larger than the
bolt.

A diagram showing a recommended bolt tightening sequence is normally supplied with each
insulating gasket set.

Common Vendors for Insulating Gasket Kits

Common vendors who manufacture and supply insulating gaskets are

PSI
Pikotek
Central Plastics
Garlock
Trojan
Lemons
Advanced Products and Systems

Information needed for Ordering Flange Insulating Kits

To order an insulating gasket kit, the following information needs to be provided:

Flange Specification (ANSI/ASME, DIN, API, MSS SP44, BSI, AWWA Standard)
Nominal Pipe Size, Pressure Rating, and Bore Size
Operating Pressure, Temperature, and Media
Gasket type (D/E/F/O)
Required Seal Material

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 Isolating Sleeve Material
Isolating Washer Material
Metal Washer Material
Quantity

Few more Resources for you…

Methods for Checking Flange Leakage
Guidelines on selection of various types of Flanges
Few points on Gaskets for leak Proof Flanged joints
PROCEDURE FOR FLANGE-BOLT TIGHTENING OF VARIOUS SIZES OF FLANGES
Functions of Gaskets for leak-proof Flanged joints

Reference

https://blog.projectmaterials.com/flanges/flange-isolation-kit/

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