Flange Insulation Kit

The growth of long distance underground pipeline systems increases the need for special
protective measures against external corrosion. The aggressive nature of the ground, the effect of
stray currents from nearby installations and the damaging potentials created by electro chemical
reaction in the earth have a deterioratory effect on pipelines and demand reliable long term
corrosion protection measures. Experience during recent years has shown that the cathodic
protection together with a high grade passive corrosion protection by application of coating on
the pipeline, provides a most efficient and economical solution.

Insulating joints at the flange points in a pipeline have a very important part to play in reducing
the cost of the cathodic protection systems.

Application of Flange Insulation kits

 To limit the extent and cost of cathodic protection current to only those pipes that need to
be protected from the main cathodic protection system.
 To electrically "split up" long pipelines into distinctive cathodic protection systems.
 To isolate a pipeline to ensure that cathodic protection or stray electricity currents do not
cause increased corrosion, or cause a hazard.
 To isolate piping systems where dissimilar metals are present.
 To eliminate static loading charge transfer in discharge or loading operations at oil
storage terminals.

Types of Kits

Insulating sets are generally available in three types, depending on the flange configuration .
Each set comprises of one central gasket either flat or oval ring type joint section depending on
flange type, one full length insulating sleeve per bolt, two insulating washers and two back-up
steel washers per bolt. The steel washer is provided to protect the insulating washer from damage
by the nut.

It is recommended that for complete protection a self adhesive tape be wrapped around the
outside of the flange to prevent the ingress of conducive foreign material.
  Type D gaskets are designed to fit into the grooves of ring-type-joint flanges.
 Type E gaskets are designed to fit flat faced flanges.
 Type F gaskets are designed to fit raised face flanges.

One piece integral sleeve and washers are also commercially available. The isolating washers
and steel washers are generally 1/8" or 3.2mm thick.

Materials

 For flat gasket commonly used materials are reinforced phenolic laminate, either plain or
neoprene coated. OR
High grade electrical quality compressed asbestos fibre.
 For ring type central gasket commonly used material is reinforced phenolic laminate.
 For sleeves and washers commonly used material is reinforced phenolic laminate.

Sleeves are available in following materials:

Mylar, Polyethylene, Phenolic, Silicon Glass, Epoxy Glass etc. Polyethylene is suitable upto
66°C, Phenolic upto 107°C and Mylar upto 180°C.

Neoprene faced phenolic gaskets are widely used for insulation in the Gas and Oil industry
because the soft neoprene rubber provides good sealing qualities. Gaskets made from asbestos
sheet are specially formulated to provide good electrical insulating properties. They are used in
applications where very large diameter flanges are used.

Applicable Standards

 BS 2572 - Specification for Phenolic laminated sheet and epoxy cotton fabric laminated
sheet.