Experience Counts!   LineBacker® Flange Isolation Kits Description Benefits/Features Specifications Warranty Installation How to Order Typical Specification Resources Related Products Description Flange Isolation Kits consist of an isolating gasket and isolating sleeves and washers which are all correctly sized for the application and conveniently packaged to minimize the possibility of lost component parts during installation. Isolating gaskets may be specified as either "E" or "F" type while single, double or one-piece sleeve and washer sets are offered as options for varying degrees of electrical isolation between the flanges. In addition, a wide variety of material options exist for both isolating gaskets and sleeve and washer materials. The Gasket LineBacker® sealing gaskets utilize a patented rectangular sealing element, referred to as a “quad” ring, in combination with a unique groove design to effectively seal and isolate flanges of all types. With the unique “quad” ring design, elastic memory is provided for elastomers not normally associated with this characteristic. Materials such as AFLAS, TFE (Teflon) and KALREZ may therefore be used as sealing elements which dramatically increases the options available for matching gasket materials to service and environmental conditions. This greater variety of materials also provides excellent temperature and chemical range compatibility. LineBacker® sealing gaskets are self energizing with theoretical near zero “m” and “y” factors resulting in effecting a positive seal without excessive bolt loads required with flat gaskets. Before Tightening The flange faces come into contact with the sealing elements, which extend slightly above the surface of the retainer. As the flange is tightened the sealing elements are compressed and move sideways into the inclined portion of the groove, developing a high unit pressure against the flange faces. After Tightening The flange faces have come into firm contact with the retainer, thus encapsulating the sealing elements within grooves. At the same time, the unique LineBacker seal configuration provides elastic memory for elastomers not normally associated with this characteristic - resulting in a simple flat gasket with extremely high loading and self energizing characteristics without adverse cold flow problems. TYPE E GASKET The gasket retainer extends out to the O.D. of the flange. Holes are cut in a type "E" gasket at the bolt circle to accommodate threaded studs or bolts. TYPE F GASKET The gasket retainer extends out to the I.D. of the bolt circle. Sleeves and Washers Single Washer Set Single washer set flange isolation kits include the following items for each bolt: One - 1/8" thick steel washer One - Isolating Washer One - Isolating Sleeve Application Considerations In buried applications, single washer configurations may be used to allow the Cathodic Protection (CP) current to reach the nuts and bolts. If desired, nuts on the opposite side of the cathodically protected flange may be included as part of the CP system. Double Washer Set Double washer set flange isolation kits include teh following components for each bolt: Two - 1/8" thick steel washers Two - Isolating washers One - Full length isolating sleeve Application Considerations Double washer configurations may be used for added protection against the possibility of “shorting out” the nuts and bolts. In addition, double washer sets electrically isolate the nuts and bolts from both flanges. One-Piece Sleeve and Washer Sets One-piece sleeve and washer set flange isolation kits include the following items for each bolt: Two - 1/8" thick steel washers One-One-piece isolating sleeve Application Considerations Easier to install, one-piece sleeves also allow the inspector a visual indication of sleeve usage. Due to the relatively low compressive strength of this material, its use is not recommended for high pressure or large diameter flanges that require high torque loads. Note: G-10 One-Piece sleeve/washer assembly available for additional strength and convenience. Gasket Benefits/Features Eliminates Flange Leaks. Guards against blowouts. Protects against fire and hostile environments. Usable with any type of flange. Matches gasket materials to service conditions. Lowest possible clamp and compressive load. Increases gasket life. Insulating version is both a positive seal and a superior insulator. Sizes All standard ANSI and API flange sizes from 1/2" and above. Custom odd sizes and shapes. Pressure Ratings All ANSI and API rated flanges. Pressures from hard vacuum to 50,000 psi and higher. Isolating Gasket Retainer and Seal Element Options Suggested Flange Isolation Material Compatibility Chart Warranty All products are warranted against failure caused by manufacturing defects for a period of one year. Any product found to be so defective and returned within one year from date of shipment will be replaced without charge. The above warranty is made in lieu of, and we disclaim, any and all other warranties, expressed or implied, including the warranties of merchantability and fitness for a particular purpose, and buyer agrees to accept the products without any such warranties. We hereby disclaim any obligation or liability for consequential damages, labor costs or any other claims or liabilities of any kind whatsoever. Installation Open packaging to inspect and determine that components are as specified. Check the gasket I.D. It should be no greater than the flange I.D. Flanges shall be free of pits, gouges, rust, debris, oil and grease. Surface finish shall be no greater than 250 RMS. Refinish flange faces if corrective measures do not meet the foregoing. Check flange and bolt hole spot facings for burrs, etc… and clear from facings. Check bolts and nuts and clean. Apply non-conductive lubricant to all threads and flange side of nuts. Align flanges so they are concentric and parallel and install gasket carefully. USE NO LUBRICANT, GREASE OR ADHESIVES ON EITHER THE GASKET OR FLANGE FACES, Guard against damaging sealing element. Line up bolt holes with non-tapered drift pins using three at 120° degrees separation (particularly large flanges), or at least two at 180° degrees separation. Install studs,nuts and washers. Initially cross-tighten bolts until flange to gasket contact has been made. Check for a flange segment that may show a gap or separation between gasket and flanges, using flashlight, calipers, or feeler gauge. If one exists, the flanges are not parallel. Directly 180° opposite widest part of indicated gap, loosen nuts, even if only finger tight, one or more turns. Return to segment with gap and tighten until both flanges are in contact with gasket retainer. This procedure is necessary to prevent restriction of flange rotation over the fulcrum formed by the outer edge of the two raised faces at points in contact with gasket retainer. The restriction will cause exceptionally high flange to gasket clamp loading at this point, with possible damage to gasket retainer, PLUS diverting necessary clamp loading bolt torque energy to correcting alignment on the opposite segment. Re-tighten loosened nuts and proceed with torqueing of the bolts according to PSI diagram, to 10-15% of specified torque. Remove drift pins and replace with bolts, nuts and washers, tightened to the same values as others in place. Repeat torque sequence, increasing to 50% of balance. Repeat tightening to final torque. Optional – it is always a good policy to go completely around flange checking bolt to bolt for proper torque, particularly on large diameter piping systems. All the above should be done with torque wrenches (mechanical and hydraulic) or with a stud tension measuring device. Always wear appropriate safety equipment! Important: Check gasket for flange type on which to be used (ie). Slip or weld-neck etc…If in doubt do not install, consult supplier or PSI. To provide even sealing pressure on a flange gasket it is recommended that the bolts be “snugged” up in the sequence shown on chart until the flange faces are in contact with the gasket. After the flange faces are in contact with the gasket firmly tighten the bolts in the same sequence. Note: Although this diagram shows 24 bolts, the same basic procedure should be used with flanges having more or less bolts. When installing gaskets made of compressible dielectric material, cold; “hot flow” of the gasket material may occur under operating conditions, resulting in loss of bolt pressure. It is advisable therefore, to re-tighten bolts after operating temperature has been reached – preferably at zero line pressure and ambient temperature. Under no circumstances should the system be allowed to return to operating temperature after the initial cycling to ambient temperature without checking and re-tightening bolts where needed. Suggested torque values for PSI sealing gaskets. How To Order To order GasketSeal® Sealing/Isolating Gaskets please indicate the following: Quantity Nominal Pipe Size Pressure Rating Gasket Type: E or F Gasket Style: GasketSeal® Retainer Material Sealing Element Weld neck or slip-on application Note all special requirements. Contact your local distributor or Pipeline Seal & Insulator, Inc. Distributor Locator Contact PSI Typical Specification General/Economical Materials for flange isolation kits on pipes containing water, aqueous fluids or natural gas (up to 220°F., 104°C) shall consist of the following components: Isolating and Sealing Gasket One full faced isolating and sealing gasket, LineBacker® Sealing Gasket Type “E”, 1/8” thick, phenolic retainer containing a precision tapered groove to accommodate the controlled compression of a EPDM quad-ring sealing element. Sealing element placement shall accommodate either flat, raised or RTJ face flanges. The quad-ring seal shall be pressure energized. The phenolic retainer shall have a 500 volts/mil dielectric strength and a minimum 25,000 psi compressive strength. The full faced flange isolating gasket shall be 1/8” less in I.D. than the I.D. of the flange in which it is installed. Full Length Bolt Isolating Sleeves One full length Mylar sleeve (extending half way into both steel washers) for each flange bolt. The Mylar shall be a 1/32 inch thick tube with a 4000 volts/mil dielectric strength and water absorption of 0.8% or less. Washers Two, 1/8 inch thick, glass clad phenolic isolating washers for each bolt. Their compressive strength shall be 33,000 psi, dielectric strength 500 volts/mil and water absorption 1.6% or less. Two, 1/8 inch thick steel washers for each bolt. The I.D. of all washers shall fit over the isolating sleeve and the steel and isolating washers shall have the same I.D. and O.D. Quality Flange Isolation Kits shall be manufactured at a facility that has a registered ISO 9001:2000 Quality Management System. Submittals shall include copy of valid registration. Availability Kits shall be manufactured by Pipeline Seal and Insulator, Inc., Houston, Texas, U.S.A., Telephone: 713-747-6948, Facsimile: 713-747-6029, www.pipelineseal.com. e-mail: info@psipsi.com Performance suitability and material compatibility shall be determined by the user. Typical Specification for General/Economical Applications in PDF Format Top of the Line Materials for flange isolation kits on pipes containing natural gas, oil and aqueous fluids (up to 280ºF, 138ºC) shall consist of the following components: Isolating and Sealing Gasket One full faced isolating and sealing gasket, LineBacker Type “E”, 1/8” thick, G-10 retainer containing a precision tapered groove to accommodate the controlled compression of a Teflon (or Viton) quad-ring sealing element. Sealing element placement shall accommodate either flat, raised face or RTJ flanges. The quad-ring seal shall be pressure energized. The G-10 retainer shall have a 550 volts/mil dielectric strength and a minimum 50,000 psi compressive strength. The full faced flange isolating gasket shall be 1/8” less in I.D. than the I.D. of the flange in which it is installed. Full Length Bolt Isolating Sleeves One full length G-10 sleeve (extending half way into both steel washers) for each flange bolt. The G-10 shall be a 1/32 inch thick tube with a 400 volts/mil dielectric strength and water absorption of 0.10% or less. Washers Two, 1/8 inch thick, G-10 isolating washers for each bolt. Their compressive strength shall be 50,000 psi, dielectric strength 550 volts/mil and water absorption 0.10% or less. Two, 1/8 inch thick steel washers for each bolt. The I.D. of all washers shall fit over the isolating sleeve and the steel and isolating washers shall have the same I.D. and O.D. Quality Gaskets shall be manufactured at a facility that has a registered ISO 9001:2000 Quality Management System. Submittals shall include copy of valid registration. Availability Gaskets shall be manufactured by Pipeline Seal and Insulator, Inc., Houston, Texas, U.S.A., Telephone: 713-747-6948, Facsimile: 713-747-6029, www.pipelineseal.com. e-mail: info@psipsi.com Performance suitability and material compatibility shall be determined by the user. Typical Specification for Top-of-the-Line Applications in PDF Format      Resources Sealing Gaskets A concise 12 page booklet that includes all PSI Sealing Gaskets including specifications, material compatibility charts and features. PDF File Size = 1,057KB. Flange Isolation Kits. A concise 12 page booklet that includes all PSI flange isolation kits. PDF File Size = 532KB. Related Products ElectroStop® Isolating Fittings