Flange Insulation Gaskets Kit

 

Flexiteck 

UK 

 

Flange Insulation Gaskets Kits

The flange insulation kit manufactured by Star 21 International prevents all kinds of leakages while protecting flanged joints from corrosion using static currents. Our insulation gasket kits are widely used in all industries from refineries to chemical plants all over Singapore, and they have passed ASTM D3850-12 Fire Safe, an analysis that was performed by SGS TGA.

 

Style : 280

 

Style 280 flange insulation gasket kit is designed to maintain the integrity and reliability of the pipeline through corrosion protection. They provide an effective seal and an electrical isolation to flanges by eliminating metal to metal contact. A static current is halted to prevent corrosion and aid in the cathodic protection of the pipe.

 

To meet the requirements of all customers our kits are available for flanges of all sizes ranging from ½” to 144” in all ANSI & API standards.

 

 

Model : F

Model F is made to fit only the raised face portion of the flange. As there are no bolt holes in this type, the inside diameter of the bolt hole circle is slightly smaller than the outside diameter of the gasket, assuring an exact, automatic positioning of the gasket. Model F comes in plain face, nitrile, or neoprene face phenolic, as well as a variety of high-temperature materials like phenolic and nitrile.

 

 

 

   

 

 

INSULATING SLEEVES AND WASHERS

 

 

Insulation sleeves are manufactured of high density polyethylene. The washers are available as NEMA grade LE phenolic, G10, G11, and Mylar in a full range of sizes.

Each insulating washer has a thickness of 1/8” and a zinc plated steel washer is provided to protect the insulating washer from being damaged by the nut.

 

TECHNICAL SPECIFICATION FOR NEOPRENE PHENOLIC GASKET

Dielectric Values (VPM) : 500

Compression Strength (PSI) : 25000

Water Absorption (%) : 1.6

Tensile strength (PSI) : 20000

Operating Temp.(deg. C) : -54 ~ +79
 

  

COMPONENTS OF A FLANGE INSULATION SET

 

Flange insulation sets comprise the following components which ensure that full electrical isolation is achieved:

Insulating gasket which is fitted between the flanges

Insulating sleeve per flange bolt

Insulation washers per flange bolt

Metal backup washers per flange bolt

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Model :   E

 

Model E is a full-face gasket with the same outside diameter as the flange. The precision-cut bolt holes in the design facilitate proper alignment of the gasket during installation & foreign materials are prevented from shorting the flange insulation. Model E is available with a phenolic face, a nitrile or neoprene face, and a variety of high-temperature materials. 

 

 

 

 

 

 

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Flange Gasket Kit

 

Model : L-seal

The L-seal flange insulation kit contains one RF or FF insulation gasket manufactured from Nema grade G-10 glass reinforced epoxy retainer with a Nitrile, Viton or Teflon seal, two insulating washers manufactured from Nema grade G-10, two steel (sae zinc plated steel) back-up washers and one Mylar insulating sleeve having a 1/32” wall thickness for each bolt.

 

 

 

 

 

Gasket Material

	Plain Phenolic	Neoprene Faced Phenolic	Reinforced PTFE	G-7 Epoxy/Glass	G-10 Epoxy/Glass	G-11 Epoxy/Glass
Dielectric strength Volts/Mill	500	500	350	350	550	550
Compressive strength psi	25000	25000	2300	40000	50000	50000
Water absorption %	1.6	1.6	0.01	0.07	0.1	0.1
Tensile strength psi	20000	20000	1450	25000	45000	43000
Operating tempo F	-65 to +220	-65 to +175	-320 to +500	-320 to +450	-320 to +280	-320 to +349
Operating tempo C	-54 to +104	-54 to +79	-196 to +260	-196 to +232	-196 to +138	-196 to +176

 

Seal Material

	Nitrile	Viton	Teflon	Neoprene	EPDM
Operating tempo F	-40 to +260	-20 to +350	-320(-20) to +450(+350)	-40 to +250	-40 to +250
Operating tempo C	-40 to +121	-29 to +177	-196(-29) to +232(+177)	-40 to +121	-40 to +121

 

 

 

 

 

 

 

 

Sleeve Materials

The typical sleeve materials used are Phenolic, Mylar, G7 Silicone Glass, G10 Epoxy Glass, and G11 Epoxy Glass. The sleeves are available in the standard bolts sizes, as well, they can also be customized. They are also available as one-piece integral sleeves and washers which provide superior compression strength. Integral sleeves are available in sizes between 1-½ inches.

	Mylar	Nomex	G7 Silicone Glass	G-10 Epoxy / Glass	G-11 Epoxy / Glass
Dielectric strength Volts/Mil	4000	400	350	550	550
Water absorption %	0.8	N/A	0.1	0.1	0.1
Operating temp %	-79 to +300	-65 to +450	-320 to +450	-200 to +302	-50 to +392
Operating tempo C	-59 to +149	-54 to +232	-196 to +232	-128 to +150	-45 to +202

 

Washer Material

The standard thickness of washers is 1/85”, and they fit insulating sleeves in a full range of bolts sizes.

	Plain Phenolic	G7 Silicone Glass	G-10 Epoxy / Glass	G-11 Epoxy / Glass
Dielectric strength Volts/Mil	500	350	550	550
Compressive strength psi	25000	40000	65000	50000
Water absorption %	1.6	0.07	0.1	0.1
Tensile strength psi	20000	25000	50000	43000
Operating tempo F	-65 to +220	-320 to +450	-200 to +320	-50 to +392
Operating tempo C	-54 to +104	-196 to +232	-128 to +150	-45 to +202

 

Flange insulation gasket kits are manufactured to fit the flange dimensions of ANSI, API, AWWA, MSSSP44, B.S.10, DIN 2633, 2634, etc.

 

L-SEAL GASKET

 

L-seal gaskets are the most effective in static sealing. The elastomer sealing element is encapsulated in the electrically insulated retainer and it permits only micro-exposure of the seal to hostile environments of fire, chemicals and corrosive fluids.

 

 

 

ADVANTAGES OF THE L-seal

 

Can be utilized with mismatched flanges 

Can be utilized with misaligned flanges

Can be used in place of RTJ or BX rings

Little initial torque required

No re-torquing required

Sealing ring cannot be left out

Seal design tested from 0 – 100,000 psi

Reusable

Compensates for pressure fluctuations, compression changes, vibrations, temperature, etc.

Greatly reduces human error during installation

Large selection of materials available

Three to four times the dielectric strength necessary

 

 

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Model : O-seal

 

Model : O-seal, manufactured by Star 21 International, has excellent sealing and insulating ability, and it is available in different sizes to fit all types of flanges.

 

 

 

Description

·       The sealing elements are encapsulated in a specially designed groove to avoid being broken when the bolt torque is not equal.

·        The materials such as Nitrile, EPDM, VITON and Teflon can be used as sealing elements in diverse environmental conditions.

·        The temperature limits of the retainer and the sealing element should be considered together when choosing the material.

·         Either an O ring seal or PTFE energized spring seal can be used, however PTFE energized spring seal is only optional.

 

Gasket Material

	Plain Phenolic	Neoprene Faced Phenolic	Reinforced PTFE	G-7 Epoxy/Glass	G-10 Epoxy/Glass	G-11 Epoxy/Glass
Dielectric strength Volts/Mill	500	500	350	350	550	550
Compressive strength psi	25000	25000	2300	40000	50000	50000
Water absorption %	1.6	1.6	0.01	0.07	0.1	0.1
Tensile strength psi	20000	20000	1450	25000	45000	43000
Operating tempo F	-65 to +220	-65 to +175	-320 to +500	-320 to +450	-320 to +280	-320 to +349
Operating tempo C	-54 to +104	-54 to +79	-196 to +260	-196 to +232	-196 to +138	-196 to +176

 

Seal Material

	Nitrile	Viton	Teflon	Neoprene	EPDM
Operating tempo F	-40 to +260	-20 to +350	-320(-20) to +450(+350)	-40 to +250	-40 to +250
Operating tempo C	-40 to +121	-29 to +177	-196(-29) to +232(+177)	-40 to +121	-40 to +121

 

 

 

 

 

 

 

 

 

 

Sleeve Materials

The typical sleeve materials are known to be Phenolic, Mylar, G7 Silicone Glass, G10 Epoxy Glass, and G11 Epoxy Glass and sleeves easily fit over standard sized flange bolts within standard size bolt holes. They are available in standard bolts sizes, as well, custom sizes can be made. They are also available as one-piece integral sleeves and washers which provide superior compression strength. Integral sleeves are available sizes through 1-1/2”.

	Mylar	Nomex	G7 Silicone Glass	G-10 Epoxy / Glass	G-11 Epoxy / Glass
Dielectric strength Volts/Mil	4000	400	350	550	550
Water absorption %	0.8	N/A	0.1	0.1	0.1
Operating temp %	-79 to +300	-65 to +450	-320 to +450	-200 to +302	-50 to +392
Operating tempo C	-59 to +149	-54 to +232	-196 to +232	-128 to +150	-45 to +202

 

Washer Material

The washer materials come as Phenolic, G7 Silicone Glass, G10 Epoxy Glass, G11 Epoxy Glass with a standard thickness of 1/85”,and insulating washers fit in insulating sleeves in a full range of bolts sizes.

	Plain Phenolic	G7 Silicone Glass	G-10 Epoxy / Glass	G-11 Epoxy / Glass
Dielectric strength Volts/Mil	500	350	550	550
Compressive strength psi	25000	40000	65000	50000
Water absorption %	1.6	0.07	0.1	0.1
Tensile strength psi	20000	25000	50000	43000
Operating tempo F	-65 to +220	-320 to +450	-200 to +320	-50 to +392
Operating tempo C	-54 to +104	-196 to +232	-128 to +150	-45 to +202

 

Available gasket type – E (3mm thickness)

Type “E” is a full-face gasket with the same outside diameter as the flange and precision cut bolt holes.

This design facilitates proper alignment of the gasket during installation. This assembly minimizes the ingress of conductive foreign matter between the portions of the flanges outside the raised face and reduces the risk of bridging.

Available gasket – F (3mm thickness)

Type “F” gaskets are made to fit the raised face portion of the flange only. As there are no bolt holes in the “F” gasket, the outside diameter of the gasket fits tightly into place ensuring a well centered position.

 

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Model : T-seal

Our insulation kit passed ASTM D3850-12 Fire Safe, analysis was performed by TGA.

 

The gasket material of mode: T-seal incorporates high-strength, glass-reinforced epoxy laminated bonded to a stainless steel core. This provides the strength of a traditional metallic gasket while maintaining complete electrical insulation between the flange faces. Seal grooves are machined through the laminate insulating material and into the stainless steel core which provides a strong base for the seal to seat into and breaks the potential leak path that is inherent in glass laminate materials. Spring-energized Teflon internal face seals are installed in the dovetail shape seal grooves to provide the reliable sealing.

 

 

 

 

Advantages and Benefits

This provides an extremely reliable sealing and insulating solution for all critical services. Seals and insulates at all pressures are classed including API 15000 psi service.

·  Seals and insulates at all pressures classed including API 5000 psi service

·  Withstands severe service conditions including large bending moments, vibration, temperature and pressure cycling

·  Designed to withstand corrosive environments, including high concentrations of CO2, H2S, produced water, etc.

·  Outstanding insulation properties for catholic protection

·  Pressure-activated seals provide high confidence sealing and eliminate costly leaks

·  Gasket is sized to the bore to protect flange faces from media-induced corrosion and flow-induced erosion

·  Prevents turbulent flow at flanged connections

·  Mitigates galvanic corrosion in dissimilar metal flanges

·  Available to match any flange specification (ANSI, API, MSSP, BS, DIN, AS, others)

·  Can mate mismatched RTJ with raised-face flanges>

·  Easy installation, make up and removal

Stainless steel core

The standard stainless steel core is 316. Special materials such as duplex stainless steel, Inconel stainless steel are can be made4 according the requirements.

 

Glass-reinforced epoxy

The standard glass-reinforced epoxy material is NAME G10; G11 is available when the temperature requirement is higher.

 

	G10 Bonded	G11 Bonded
Dielectric strength Volts/Mill	550	550
Compressive strength psi	65000	50000
Water absorption %	0.005	0.085
Flexural strength psi	65000	60000
Tensile strength psi	50000	45000
Operating tempos	-65 to +280	-50 to +349
Operating tempos	-54 to +138	-45 to +176

 

 

Seal

The standard sealing material is Spring-energized Teflon which suitable for most of working conditions. Meanwhile, the other materials like VITON also available.

 

	Nitrile	Viton	Teflon
Operating tempos	-40 to +250	-20 to +350	-320 to +450
Operating tempos	-40 to +121	-29 to +177	-196 to +232

 

Sleeve Materials

The typical sleeve materials are known to be Phenolic, Mylar, G7 Silicone Glass, G10 Epoxy Glass, and G11 Epoxy Glass and sleeves easily fit over standard sized flange bolts within standard size bolt holes. They are available in standard bolts sizes, as well, custom sizes can be made. They are also available as one-piece integral sleeves and washers which provide superior compression strength. Integral sleeves are available sizes through 1-1/2”.

	Mylar	Nomex	G7 Silicone Glass	G-10 Epoxy / Glass	G-11 Epoxy / Glass
Dielectric strength Volts/Mil	4000	400	350	550	550
Water absorption %	0.8	N/A	0.1	0.1	0.1
Operating temp %	-79 to +300	-65 to +450	-320 to +450	-200 to +302	-50 to +392
Operating tempo C	-59 to +149	-54 to +232	-196 to +232	-128 to +150	-45 to +202

 

Washer Material

The washer materials come as Phenolic, G7 Silicone Glass, G10 Epoxy Glass, G11 Epoxy Glass with a standard thickness of 1/85”,and insulating washers fit in insulating sleeves in a full range of bolts sizes.

	Plain Phenolic	G7 Silicone Glass	G-10 Epoxy / Glass	G-11 Epoxy / Glass
Dielectric strength Volts/Mil	500	350	550	550
Compressive strength psi	25000	40000	65000	50000
Water absorption %	1.6	0.07	0.1	0.1
Tensile strength psi	20000	25000	50000	43000
Operating tempo F	-65 to +220	-320 to +450	-200 to +320	-50 to +392
Operating tempo C	-54 to +104	-196 to +232	-128 to +150	-45 to +202

 

Available gasket type – E (6.25mm thickness)

Type “E” is a full-face gasket with same outside diameter as the flange and precision cut bolt holes.

 

This design facilitates proper alignment of the gasket during installation. This way, there is less chance of conductive foreign matter getting between the parts of the flanges that aren't raised.

 

Available gasket type – F (6.25mm thickness)

Type “F” gasket are made to fit the raise face portion of the flange only. As there are no bolt holes in the “F” gasket, the outside diameter of the gasket fit tightly into place assuring a well centered position.

 

 

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Model :  D

It’s specially designed to fit into the ring groove of RTJ flanges. They are manufactured of a medium weave, fabric reinforced phenolic material and are sized to ANSI and API specifications, available in basic oval, octagonal shape, also available are BX gaskets.

Our Flexiteck insulation kit passed ASTM D3850-12 Fire Safe, analysis was performed by SGS TGA