FLANGE INSULATION

GASKETS

trusted. worldwide
 ISOMAX Flange Insulation Sets

Klinger ISOMAX 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. They 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 gasket, one insulation, sleeve, two insulating
and two plated 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 electro-chemical 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:

• G10 Sleeves
• G10 Insulation Washers
• Zinc Plaited Metal Washers
• Others combinations on request

1
 ISOMAX Flange Insulation Sets
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 for a recommendation.

ISOMAX Gasket recommendations for ANSI B16.5 Raised Face Flange Class
√ - recommended ; x - not recommended

Pressure Class Rating ANSI B16.5 Raised Face

Gasket 150 300 600 900 1500 2500

Style LPS    * * 

HPS-High      
Pressure Spring
Energised PTFE

*subject to a technical evaluation-please contact Klinger

The above table is applicable to Raised Face Flanges. For ANSI B16.5 & API 6A Ring Joint
Flanges(RTJ)

Low Temperature Duty

Some applications require the use of insulating gaskets at low temperatures. In this case, care
must be taken with materials that contain an elastomeric component since elastomers will harden
as they pass through the glass transition temperature losing their resilience. The temperature at
which this occurs is dependent on the elastomer.
Klinger would recommend a PTFE (Teflon) based seal.

Assembly of Insulating Gaskets

Assembly of insulating gaskets requires the same good fitting practice used to assemble standard
gaskets.
When installing a gasket, the correct installation procedures should be followed and the flange
surface finish (Ra) should be between 3.2 and 6.3 micro meters.
For other Klinger insulating gasket materials, please consult Klinger.

trusted. worldwide 2
 ISOMAX HPS Flange Insulation Sets

The HPS is a high strength and high reliability flange gasket

designed for electrical insulation and sealing in very critical
service applications. The gasket is manufactured using a
composite seal retainer material bonded to a high integrity
metal core, 316 Stainless Steel is standard. The spring
energized PTFE seal offers excellent sealability even at low
loads.

 The HPS gasket is a high reliability gasket used for General Characteristics
both insulating and general sealing applications
 Flange insulation as well as cathodic
 The HPS is suitable in all services up to and
protection
including ANSI 2500# and API 15,000# classes.
 Reduces galvanic corrosion in dissimilar
 Each HPS insulation set comprises one central
metal materials used in flange joints
insulating gasket, one insulation sleeve per bolt and
 Allows mismatched ring-joint to raised-face
two insulating and two plated steel washers per
flanges to be effectively sealed. HPS will
bolt.
seal in ring joint, raised-face and flat
Materials face/slip-on flange applications.
 Will withstand corrosive environments
• Metallic Core: 316 Stainless Steel including high CO2, H2S and processed
• (Duplex & Inconel available) water
• Gasket Insulating Material: G-10 Glass Reinforced  The bore construction protects flange faces
Epoxy (GRE) as standard (G-11 available) from media-induced corrosion and flow-
• Seal Material: Spring-energized PTFE as standard induced erosion.
• Insulating Sleeve Material: GRE as standard  The pressure energised seal allows for
• (Mylar available) reduced flange assembly stress
• Insulating Washers Material GRE (standard)  Easy to install and remove
• Steel Washer Material Zinc Plated Steel as standard  Reusable seal retainer and seals
(stainless steel available).  Suitable for all ANSI and API rated flanges
 High strength laminate material reduces
failure due to over compression
HPS Design
The design of the HPS gaskets incorporates a high-strength reinforced epoxy laminate bonded to a 316
stainless steel core as standard (other core materials available). This design results in the gasket having the
strength of a traditional metallic gasket while at the same time allowing complete electrical insulation
between the flange faces.
PTFE Spring-energised seals are installed into machined grooves to provide a pressure-activated sealing
system that allows the HPS to be used as a high pressure insulating gasket.

Electrical Insulation
The HPS distinguishes itself by providing electrical flange insulation in a high-strength gasket.
The HPS significantly reduces the potential for electrical conductivity between two flange faces by providing
a non-conducting, non-metallic interface.
This eliminates potential corrosion resulting from dissimilar metals making contact or from ground induced
current corrosion of metal components in pipeline systems.
The HPS is an effective sealing system used in breaking electrical conductivity in piping systems with
cathodic protection.
The HPS’s steel core and construction enables the gasket to withstand higher system pressure, pressure
cycling, over torquing than conventional insulating gaskets.

3
 ISOMAX HPS Flange Insulation Sets

Sealing raised face to Ring Joint

flanges
The positioning of the sealing elements of the HPS
gasket are designed to fit Raised Face, Flat Face and
Ring Type Joint flanges.
Because of this design we are able to replace the old
design of Phenolic RTJ gaskets commonly
designated Type “D-Ring Joint Gasket” which were
limited in their ability to take high stresses or
excessive bolt loads which often resulted in gasket
fracture, damage or failure in service.
Because the HPS uses pressure-activated sealing elements which are designed to sit inside the ring
groove on RTJ flanges it has the additional advantage of allowing the HPS to seal mismatched RTJ to
raised face or flat faced flanges. This can be of great benefit to the customer when replacing flanges or
valves using current stock inventory that may have a different flange face than the mating flanges in situ.

HPS Flange Insulation Kit Components

The gasket set comprises the following as listed below:

Insulation Kit Contents:

Insulating facing: G-10 glass reinforced epoxy resin standard. G11 also available on request.
Seal: Spring energised PTFE
Core: Stainless steel 316
Standard Thickness: 7.0 mm.
Insulating Washers: G-10 glass reinforced epoxy resin (other materials are available)
3.2mm thickness
2 washers per bolt
Steel Washers: Zinc-plated steel,
3.2mm thickness (stainless steel washers also available)
2 washers per bolt
Insulating Sleeves: G-10 glass reinforced epoxy resin.
(Mylar and Nomex also available)
1 insulating sleeve per bolt

Insulation Kit Properties

Material type: G-10 Glass-reinforced epoxy resin G-11 High temperature resin
Compressive 50,000psi - minimum 50,000psi - minimum
strength:
Dielectric strength: 24.1-31.5 kV/mm 24.0 kV/mm
Maximum temp: 150°C 200°C
Water absorption: 0.1% - maximum 0.1% - maximum
Flexural strength: 65,000psi 57,700psi
Tensile strength: 50,000psi 41,000psi
Temperature range: - 130°C to 150°C - 46°C to 200°C
(limited by gasket material) (limited by gasket material)
Seal: Spring-energised PTFE

trusted. worldwide 4
 ISOMAX LPS Flange Insulation Sets

The LPS gasket is an economical seal for electrical flange isolation and general applications requiring
higher performance capabilities than those offered by neoprene-faced phenolic gaskets.
The gasket comprises grooves that are machined into high strength G10 laminate and in to which are
inserted either spring energized PTFE or Neoprene o-ring seals which offer excellent sealability at low
loads.
The LPS gasket is highly suited for use in classes up to and including class 600 lb gasket.

The LPS gasket is available in full face (Type E) and ring style (Type F) configuration.

Ring Face Full Face

General Properties
• Gives a high sealing reliability in low pressure system.
• Excellent electrical insulation when used on cathodic protection systems.
• Is suitable for most hydrocarbons services subject to seal ring material selection.
• Reduces galvanic corrosion in dissimilar metal flanges.
• Design eliminates media-induced corrosion and flow-induced erosion from flange faces.
• Design requires reduced flange/bolt assembly stress.
• Easy installation and removal.
• Suitable for all ANSI rated flanges up to class 600 lb.

Materials
Gasket Insulating Material & Washers: G-10 Glass Reinforced Epoxy (GRE) as standard (G-11 high-
temperature grade also available).
Spring energized PTFE or O-Ring pressure activated seal: PTFE (spring energized) as standard
(Neoprene is also available).
Insulation sleeves: GRE (standard) or Nomex for high temperature service.

5 trusted. worldwide
 ISOMAX Flange Insulation Sets

LPS Flange Gasket Advantages & Benefits

 Low pressure sealing (ANSI class 150, 300 and 600) service.
 Seals are pressure activated.
 High strength laminate material reduces failure due to excess compression.
 Excellent electrical insulation when used on cathodic protection systems
 Design eliminates media-induced corrosion and flow-induced erosion from flange faces
 Reduces galvanic corrosion in dissimilar metal flanges.
 Also available with a variety of elastomeric seals.
 Easy installation, assembly and removal as design requires reduced flange/bolt assembly stress.
 Flanges do not have to be spread as would be the case with RTJ gaskets. The LPS easily slips
in place.
 Gasket is self-aligning and centering, quick to install, no special tools are required.
 Maintenance-free, corrosion resistant design.

Insulation Kit Contents:

Insulating facing: G-10 glass reinforced epoxy resin

Seal: Spring energised PTFE ( Neoprene also available)
Thickness: 3.2mm.
Insulating Washers: G-10 glass reinforced epoxy resin (other materials are available)
3.2mm thickness
2 washers per bolt
Steel Washers: Zinc-plated steel,
3.2mm thickness (stainless steel washers also available)
2 washers per bolt
Insulating Sleeves: G-10 glass reinforced epoxy resin.
(Mylar and Nomex also available)
1 insulating sleeve per bolt

Core Materials:
Material type: G-10 Glass-reinforced epoxy resin G-11 High temperature resin
Compressive 50,000psi - minimum 50,000psi - minimum
strength:
Dielectric strength: 24.1-31.5 kV/mm 24.0 kV/mm
Maximum Temp: 150°C 200°C
Water absorption: 0.1% - maximum 0.1% - maximum
Flexural strength: 65,000psi 57,700psi
Tensile strength: 50,000psi 41,000psi
Temperature range: - 130°C to 150°C - 46°C to 200°C
(limited by gasket material) (limited by gasket material)
Seal: Spring-energised PTFE (Neoprene rubber also available)

6
 Other Flange Insulation Sets

Type E – Full Face Gasket

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.

Type F – Ring Gasket

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

Type D – Ring Joint Gasket

Type D insulation gaskets use the same basic materials as
the standard insulation sets but are designed for RTJ
flanges. The gasket is manufactured from reinforced
phenolic resin. Type D gaskets have an oval cross-section
and are suitable for low pressure up to class 600# rating
applications.
Care must be taken during installation of this gasket so that
it is not overstressed during bolt up.

Standard Sleeve & Washer Materials in the Set are:

• Mylar Sleeves
• G10 Insulation Washers
• Stainless Steel Metal Washers
• Other combinations on request

7 trusted. worldwide
 Flange Insulation Sets

Gasket recommendations for ANSI B16.5 Raised Face Flange Class

 - recommended ; - not recommended; * Consult Klinger to confirm suitability

Pressure Class Rating ANSI B16.5 Raised Face

Gasket 150 300 600 900 1500 2500

Neophenolic  *    

Topchem 2003      

C-4430   *   

Topchem 2000   *   

Properties:

Dielectric Water Maximum

Component Strength Absorption Temperature
(Kv/mm) (%) (°C)

Neoprene faced Gasket 19.8 1.6 107

Phenolic
Klingersil C-4430 Gasket 21.3 10.6 400
Klinger Topchem Gasket 3.6 0.5 260
2000
Klinger Topchem Gasket 16.7 0.5 260
2003
G10 Gasket, Sleeve, 24.1-31.5 0.1-max. 150
Washer
G11 Gasket, Sleeve, 24.0 0.1 -max. 200
Washer
Mylar Sleeve 157.5 0.8 145
Phenolic Sleeve 5.5 1.0 107
Reinforced Washer 7.8 1.0 107
Phenolic

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.

8
 Flange Insulation Sets

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.

Designed to cover flanges to protect flange faces, stud bolts, and

gaskets from corrosion.
• Keeps out moisture, chemicals, saltwater, acid rain, etc.
• Keeps out foreign matter, which is critical on systems that are cathodically protected.
• Available in 316 stainless steel and Kydex plastic.
• 316 stainless steel worm gear clamp and injection fitting
• 316 stainless steel injection fitting.
• Standard gasket liner of closed cell neoprene, maximum operating temperature of
82°C.
• Optional EPDM rubber gasket liner, maximum operating temperature of
132°C.
• Optional liner of Teflon® or silicone for chemical and high temperature

• Safety relief valve optional, bleeds at 5 psi.

• Available for all size flanges.
• Standard liner Neoprene. Optional liner of Teflon® or silicone for chemical and high temperature
applications.
• Custom engineered designs available per application.

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:

Tel: +61 08 9251 1600 or Toll Free No.1300 79 82 79 (in Australia), Fax:+61 08 93509286
Email: [email protected] or [email protected]
Website: www.klinger.com.au

Subject to technical alternations

8991402 rev2

9 trusted. worldwide
 KLINGER Limited

AUSTRALIA
Western Australia – Head Office
38 McDowell Street
Welshpool WA 6106

Queensland
Unit 3, 5-7 Roseanna Street
Gladstone QLD 4680

Tel: 1300 798 279

(calls within Australia)

Tel: +61 8 9251 1688

(calls outside Australia)

NEW ZEALAND
Tel: +64 272 735 045

SINGAPORE
105 Cecil Street #07-01, The Octagon
Singapore 069534
Tel: +65 6827 9045

KLINGER Thailand
501/2 Moo 2, Tambol Mabyangporn
Amphur Ruak Daeng
Rayong 21140 Thailand
Tel: +66 3306 0154

WWW.KLINGER.COM.AU