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Saint Ferrer® Flange Isolation Kit Product CatalogComponents for Flange Insulation and Dielectric Isolation

Catalog # IK0117

Corrosion doesn’t happen

overnight

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Using Engineering Judgment The selection process involves many considerations, including but not limited to, design and mechanical properties of bolting, gaskets, and flanges at pressures and temperatures. While this guide provides technical direction you should not use it as a standalone document. This selection guide is provided as a convenience only and is intended for general information and educational purposes only. This selection guide should only be used to support engineering judgment, and not as a substitute for engineering judgment. The information provided by this selection guide is not intended in any way as engineering advice and should not be relied on as a substitute for such professional advice. Consult a licensed professional engineer and the ASME and AWWA codes, specifications, and standards prior to making final decisions regarding your flange, bolt, nut, and gasket selections

Disclaimer of Liability Numerous codes, specifications, standards, handbooks, and engineering calculations were used in developing this selection guide. Although substantial effort was put into the creation of this selection guide, it is provided “AS IS WITHOUT ANY REPRESENTATIONS OR WARRANTIES.” Westermann disclaims all expressed or implied warranties regarding your use of this selection guide and the

information this selection guide provides, including but not limited to, any warranties related to accuracy, validity, completeness, applicability, and compliance with applicable laws, regulations, codes, or standards.

Additional LiteratureUse the following documents in conjunction with this selection guide:

• ASME Boiler and Pressure Vessel Code• ASME B31.1 Power Piping• ASME B31.9 Building Services Piping• Select ASME Flange Specifications (B16.5, B16.1 and others)

Where to Get HelpFor help with this guide please contact us at

Westermann Bolt and Gasket Co. a RIEX CompanySaint Ferrer® Product DevelopmentFort Worth, TX 1-800-434-9954technical@saintferrer. comCopyright © 2017

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Insulation and the Galvanic Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Isolation and the Cathodic Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

COMPONENT SELECTION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4One and Two-Sided Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Typical Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FLANGE ISOLATION KIT TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SAINT FERRER MATERIAL PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SAINT FERRER® VOLT® SELECTION PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SAINT FERRER® VOLT® SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SAINT FERRER® KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Saint Ferrer® 105 Series Sleeve and Washer Only (S&W), Type E, and Type F Kits . . . . . . . . . . 8Saint Ferrer® 221 Series Sleeve and Washer Only (S&W), Type E, and Type F Kits . . . . . . . . . . 8Saint Ferrer® V Series / G10 Sleeve and Washer Only Kits . . . . . . . . . . . . . . . . . . . . . . 9Saint Ferrer® V Series / G10 Type E Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Saint Ferrer® V Series / BoPET-Phenolic Sleeve and Washer Only Kits . . . . . . . . . . . . . . . 10Saint Ferrer® V Series / BoPET-Phenolic Type E Kits . . . . . . . . . . . . . . . . . . . . . . . . 10

REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SELECTING A GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11SIZING KITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11KIT LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

TABLE OF CONTENTS

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INTRODUCTION

It is the aim of this catalog to present our customers with clear, direct, and relative information about our products. We trust this information will be of service to them when in the market for flange isolation components, and that our products will offer them a simple solution for their corrosion conditions. To slow the accelerated process of corrosion, our products meet the highest requirements for materials. This adds long-term value and offers a life-cycle cost benefit.

Insulation and the Galvanic CellAlthough sometimes considered a form of corrosion, galvanic corrosion is more accurately a type of corrosion mechanism because galvanic action is the basis for, or can accelerate the effects of, other forms of corrosion. Uniform attack, pitting, and crevice corrosion can all be exacerbated by galvanic conditions.

Galvanic corrosion occurs when two dissimilar conducting materials are in electrical contact. It usually consists of two dissimilar conductors in electrical contact with each other and with a common conducting fluid (an electrolyte), or it may occur when two similar conductors come in contact with each other via dissimilar electrolytes.

When two materials are in electrical contact and connected by an electrolyte, a galvanic current flows between the two. This electrically coupled system is known as a galvanic cell.

Flange insulation kits provide dielectric insulation by insulating the two materials from one another. The kits consist of an insulating gasket, bolt sleeves, nonmetallic washers, and backing washers. An insulating washer must be used under the head of the bolt and the nut to provide full dielectric insulation.

Isolation and the Cathodic Protection System

A correctly designed cathodic protection (CP) system effectively prevents corrosion. One critical element in any CP system is dielectric isolation of the protected structure.

Dielectric isolation eliminates the possibility of protective current from the CP system being conducted to buried metallic structures other than the one being protected. Dielectric isolation also helps to control or eliminate the potentially severe and localized damage caused by stray-current corrosion. Stray currents are those that leave a protected structure rather than returning along the structure lead or wire connected to an anode.

Flange Isolation Kits provide dielectric isolation by isolating the flanged joint relative to its location it the CP. The kits consist of an isolating gasket, bolt sleeves, nonmetallic washers, and backing washers. An isolating washer may be used under the head of the bolt and the nut, or on just one side making sure to leave the open side open to the cathodic protection system.

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COMPONENT SELECTION OVERVIEW

Component selection begins with determining the operating conditions of media, temperature, and required dielectric performance. The insulating gasket also has to act as a seal so depending on the conditions an optimization decision may have to be made. A gasket that is suitable for the media and temperature may not provide the maximum dielectric insulation. The sleeves and washers must also be selected to the maximum operating temperature condition. When choosing a O-ring sealing element gasket with a glass composite retainer, consider the effect of an ambient thermal transient distribution on the retainer’s flexural modulus.

Finally, the type of protection, either isolation from a galvanic cell, or as part of a cathodic protection system will determine the number of flange sides that will be protected.

One-Side ProtectionOne-side protection contains only one isolating and backing washer (single washer) per bolt (Figure 6). Use these kits in conjunction with an overall cathodic protection system such as an anode bed or impressed current system. In these systems, one side kits (sometimes called single washer kits) isolate sections of the cathodic protection system. Location of the isolating washer under either the bolt head or the nut depends on the side of the flange protected by the cathodic protection system.

Two-Side ProtectionTwo-side kits (sometimes called double washer kits) contain two isolating and backing washers per bolt installed on both sides of the flange. Two-side kits solely electrically isolate two flanges.

Typical Protection

One-Side

Two-Side

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FLANGE ISOLATION KIT TYPES

Sleeve and Washer Only – Single Sleeve and Washer Only – Double

Type E – Single Type E – Double

Type F – Single Type F – Double

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SAINT FERRER® MATERIAL PROPERTIES

Material Product ImageTemperature

(°F)

Dielectric Strength (v/mil) Color

Water Absorption

(%)

Polyethylene Isolating Sleeve 105 450 White <0.1

BoPET Isolating Sleeve 221 5000-6000 Opaque 0.1

Phenolic Isolating Washer 225 400 Brown 1.1

G10 Isolating Sleeve and Washer

285 530 Green 0.09

G10 Performance Isolating Gasket with

Nitrile sealing element

200 530 Green 0.09

G10 Performance Gasket with FKM sealing element

285 530 Green 0.09

CE Performance Isolating Gasket with Nitrile sealing element

200 400 Brown 2

CE Performance Isolating Gasket with FKM sealing element

225 400 Brown 2

CNA 1500 Isolating Gasket 400 483 Green N/A

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This section describes a procedure that may be used to select flange isolation products for the flanged joint and the technical information needed to select flange isolation products for given applications. The selection process involves collecting information about your application. To help with this process, you can use the Saint Ferrer® VOLT® table as a guide.

Note that the steps do not necessarily have to be in the following sequence as long as the information is collected.

V — Volts per mil

O — Operating conditions

L — Lowest rated component

T — Type of protection

V—Volts/mil

Specifically, you must know the required dielectric strength in Volts/mil. You might also want to know the isolation product’s maximum allowed water absorption in percent. Dielectric strength is the Voltage gradient at which dielectric failure of the isolating material occurs under the specific conditions of the test. The units are Volts/mil (mil being 1/1000th of an inch, not 1 mm). Thickness, temperature, electrical frequency, and many other factors affect a material’s dielectric strength. Therefore, when installed in the field, the dielectric strength of a material will vary from published values.

Dielectric strength is obtained by testing to ASTM D149, Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power frequencies. Water absorption is a value obtained by testing to ASTM D570, Standard Test Method for Water Absorption of Plastics. In this test, material specimens are submerged in water at an agreed upon condition, generally 23° C for 24 hours. The part’s water absorption is the increase in weight by percent found after submersion. It is not mandatory to know the maximum allowed water absorption, but doing so can help ensure a more appropriate selection.

O—Operating Conditions The media and temperature.

L—Lowest Rated Component This step is a reminder that when choosing a gasket, sleeve, and washer combination, the physical properties of the lowest rated component are the maximum physical property of the entire combination.

T—Type of Isolation Determine whether protection should be one- or two-side, i. e., whether to have washers on one or both sides of the flanged joint. Typically, one-side protection is used in conjunction with an overall cathodic protection system to isolate sections of pipe. Two-side protection merely insulates two flanges of different materials from each other.

Model No. TypeJoint

Treatment SleeveIsolating Washer

Backing Washer Gasket

Maximum Temp (°F)

Dielectric Strength (v/mil)

105-SW1 Sleeve and Washer One side Poly Phenolic Zinc Steel None 105 400

105-SW2 Sleeve and Washer Two side Poly Phenolic Zinc Steel None 105 400

105-EK1 Type E Sleeve and Washer One side Poly Phenolic Zinc Steel CNA1500 105 400

105-EK2 Type E Sleeve and Washer Two side Poly Phenolic Zinc Steel CNA1500 105 400

221-SW3 Sleeve and Washer One side BoPET Phenolic Zinc Steel None 221 400

221-SW4 Sleeve and Washer Two side BoPET Phenolic Zinc Steel None 221 400

221-EK3 Type E Sleeve and Washer One side BoPET Phenolic Zinc Steel CNA1500 221 4000

221-EK4 Type E Sleeve and Washer Two side BoPET Phenolic Zinc Steel CNA1500 221 400

V-E10N1 Type E Sleeve and Washer One side G10 G10 Zinc Steel G10 with nitrile sealing element 200 530

V-E10N2 Type E Sleeve and Washer Two side G10 G10 Zinc Steel G10 with nitrile sealing element 200 530

V-E10V1 Type E Sleeve and Washer One side G10 G10 Zinc Steel G10 with FKM sealing element 285 530

V-E10V2 Type E Sleeve and Washer Two side G10 G10 Zinc Steel G10 with FKM sealing element 285 530

V-EPN1 Type E Sleeve and Washer One side BoPET Phenolic Zinc Steel Phenolic with nitrile sealing element 200 400

V-EPN2 Type E Sleeve and Washer Two side BoPET Phenolic Zinc Steel Phenolic with nitrile sealing element 200 400

V-EPV1 Type E Sleeve and Washer One side BoPET Phenolic Zinc Steel Phenolic with FKM sealing element 221 400

V-EPV2 Type E Sleeve and Washer Two side BoPET Phenolic Zinc Steel Phenolic with FKM sealing element 221 400

SAINT FERRER® VOLT® SELECTION MATRIX

SAINT FERRER® VOLT® SELECTION PROCESS

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SAINT FERRER® KITS

Saint Ferrer® 105 Series Sleeve and Washer Only (S&W), Type E, and Type F KitsThe Saint Ferrer® 105 Series contain polyethylene sleeves providing a maximum dielectric strength of 400 Volts/mil and maximum temperature of 105° F. Selection of a .125 inch thick flange gasket completes the kit.

Model No. Type

Joint Treatment Sleeve

Isolating Washer

Backing Washer Gasket

105-SW1 S&W One side Poly Phenolic Zinc Steel None

105-SW2 S&W Two side Poly Phenolic Zinc Steel None

105-EK1 Type E One side Poly Phenolic Zinc Steel CNA1500

105-EK2 Type E Two side Poly Phenolic Zinc Steel CNA1500

105-FK1 Type F One side Poly Phenolic Zinc Steel CNA1500

105-FK2 Type F Two side Poly Phenolic Zinc Steel CNA1500

Saint Ferrer® 221 Series Sleeve and Washer Only (S&W), Type E, and Type F KitsThe Saint Ferrer® 221 Series contains biaxially-oriented polyethylene terephthalate (boPET) (Dupont trade name Mylar®) sleeves providing a maximum dielectric strength of 400 Volts/mil and maximum temperature of 221° F. Selection of a .125 inch thick flange gasket completes the kit.

Model No. Type

Joint Treatment Sleeve

Isolating Washer

Backing Washer Gasket

221-SW3 S&W One side boPET Phenolic Zinc Steel None

221-SW4 S&W Two side boPET Phenolic Zinc Steel None

221-EK3 Type E One side boPET Phenolic Zinc Steel CNA1500

221-EK4 Type E Two side boPET Phenolic Zinc Steel CNA1500

221-FK3 Type F One side boPET Phenolic Zinc Steel CNA1500

221-FK4 Type F Two side boPET Phenolic Zinc Steel CNA1500

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Model No. Type

Joint Treatment Sleeve

Isolating Washer

Backing Washer Gasket

V-SW1 S&W One side G10 G10 Zinc Steel None

V-SW2 S&W Two side G10 G10 Zinc Steel None

V-SW3 S&W One side G10 G10 AISI 304 None

V-SW4 S&W Two side G10 G10 AISI 304 None

V-SW5 S&W One side G10 G10 AISI 316 None

V-SW6 S&W Two side G10 G10 AISI 316 None

Model No. TypeJoint

Treatment SleeveIsolating Washer

Backing Washer Gasket

V-E10N1 Type E One side G10 G10 Zinc Steel G10/Nitrile

V-E10N2 Type E Two Side G10 G10 Zinc Steel G10/Nitrile

V-E10N3 Type E One side G10 G10 AISI 304 G10/Nitrile

V-E10N4 Type E Two Side G10 G10 AISI 304 G10/Nitrile

V-E10N5 Type E One side G10 G10 AISI 316 G10/Nitrile

V-E10N6 Type E Two Side G10 G10 AISI 316 G10/Nitrile

V-E10E1 Type E One side G10 G10 Zinc Steel G10/EPDM

V-E10E2 Type E Two Side G10 G10 Zinc Steel G10/EPDM

V-E10E3 Type E One side G10 G10 AISI 304 G10/EPDM

V-E10E4 Type E Two Side G10 G10 AISI 304 G10/EPDM

V-E10E5 Type E One side G10 G10 AISI 316 G10/EPDM

V-E10E6 Type E Two Side G10 G10 AISI 316 G10/EPDM

V-E10V1 Type E One side G10 G10 Zinc Steel G10/FKM

V-E10V2 Type E Two Side G10 G10 Zinc Steel G10/FKM

V-E10V3 Type E One side G10 G10 AISI 304 G10/FKM

V-E10V4 Type E Two Side G10 G10 AISI 304 G10/FKM

V-E10V5 Type E One side G10 G10 AISI 316 G10/FKM

V-E10V6 Type E Two Side G10 G10 AISI 316 G10/FKM

Saint Ferrer® V Series / G10 Type E KitsThe Saint Ferrer® V Series / G10 contain Nema Grade G10 Sleeves and Washers and a G10 Retainer/ O-Ring sealing device giving the kit a maximum dielectric strength of 530 Volts/mil and maximum temperature of 285° F when using an FKM sealing element, 250° F for the EPDM, and 200° F for the Nitrile element. Backing washers can be selected for their corrosion resistance.

Saint Ferrer® V Series / G10 Sleeve and Washer Only KitsThe Saint Ferrer® V Series / G10 contain Nema Grade G10 Sleeves and Washers giving the kit a maximum dielectric strength of 530 Volts/mil and maximum temperature of 285° F. Backing washers can be selected for their corrosion resistance.

SAINT FERRER® KITS

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SAINT FERRER® KITS

Saint Ferrer® V Series / BoPET-Phenolic Sleeve and Washer Only KitsThe Saint Ferrer® V Series / BoPET-Phenolic contains biaxially-oriented polyethylene terephthalate (boPET) (Dupont trade name Mylar®) sleeves and phenolic washers giving the kit a maximum dielectric strength of 400 Volts/mil and maximum temperature of 221° F. Backing washers can be selected for their corrosion resistance. Selection of a .125 inch thick flange gasket completes kit selection.

See 221 Series Sleeve and Washer Only

Model No. TypeJoint

Treatment SleeveIsolating Washer

Backing Washer Gasket

V-EPN1 Type E One side BoPET Phenolic Zinc Steel Phenolic/Nitrile

V-EPN2 Type E Two side BoPET Phenolic Zinc Steel Phenolic/Nitrile

V-EPE1 Type E One side BoPET Phenolic Zinc Steel Phenolic/EPDM

V-EPE2 Type E Two side BoPET Phenolic Zinc Steel Phenolic/EPDM

V-EPV1 Type E One side BoPET Phenolic Zinc Steel Phenolic/FKM

V-EPV2 Type E Two side BoPET Phenolic Zinc Steel Phenolic/FKM

Saint Ferrer® V Series / BoPET-Phenolic Type E KitsThe Saint Ferrer® V Series / BoPET-Phenolic contains biaxially-oriented polyethylene terephthalate (boPET) (Dupont trade name Mylar®) sleeves, phenolic washers and a phenolic / O-Ring sealing device giving the kit a maximum dielectric strength of 400 Volts/mil and maximum temperature of 221° F when using the FKM sealing element, or 200° F when using the Nitrile or EPDM sealing element. Backing washers can be selected for their corrosion resistance.

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Selecting A GasketThe selection of isolation kits is an optimization process: corrosion management versus seal. The selection of a gasket suitable for the conditions may not provide the corrosion protection desired. When choosing a sealing device, it is best to follow a basic sealing design principle in which friction between the contact face and sealing device is kept at a maximum.

The V-Series offers a retainer with an O-ring sealing element. For some, it is not intuitive to think that a small cross section O-ring can affect a seal. When designed with a proper closure and coupled with an adequate preload force, O-rings are capable of sealing at very high pressures.

When extended beyond the bolt circle to the flange OD, the O-ring retainer prevents some flange rotation due to the initial bolt up. However, the gasket reaction diameter is located close to the bore. Flange deflection and loss of compressive force near the bore due to system pressure is difficult to calculate. ASME Non-mandatory appendix Y flange design indicates that the gasket reaction diameter should be located close to the bore in line with the pipe wall. Moving the gasket reaction diameter closer to the bolt circle to account for flange deflection moves the fulcrum, thus changing the moment. Design of flat face flanges without metal-to-metal contact is quite challenging.

To offer a simple explanation of sealing success: O-rings are designed to be deformed. The designer is interested in how much force is needed for a given deformation since this affects leak rate and the assembly procedure. Elastomers for dynamic seals have a hardness of 70 durometer to accommodate a lower friction force. Since temperature affects rubber’s elastic modulus, stress relaxation, expansion of the elastomer, and flexural modulus of the retainer, the prediction of an elastomers O-ring seal with retainer performance depends on a projected time-temperature-squeeze history of the joint.

Sizing KitsFor full dielectric protection, it is desirable to avoid all metal-to- metal contact. To achieve this, the gasket should extend from the pipe bore as an I.D. to the most outside dimension as an OD. The sleeves should protrude just beyond the flange thickness into the isolating washers but no so much that by tightening the nut the two come in contact causing shear fracture of the sleeve. Because field conditions vary, i.e., flange to flange configurations, it is not possible to produce an exact sizing standard. If the measurements are to be exact, it is prudent to provide gasket dimensions well in advance of ordering allowing for manufacturing lead time and to cut the sleeves from tube in the field based on field measurements. We will do our best to accommodate your needs.

REFERENCE

Kit Labels

SAINT FERRER® ISO S&W

4–150 105-EK1

P/N 105EK150-040

Kit Type

Size and Class

Part Number

Model No.

SERIES LABEL COLOR

105 Yellow

221 Blue

V-Series Red

Packaging150# 300# 150# 300#

ISO Type F ISO Type F ISO Type E ISO Type E

1/2" 20 20 20 20

3/4" 20 20 20 20

1" 20 20 20 20

1-1/4" 20 20 20 20

1-1/2" 20 20 20 20

2" 20 20 20 20

2-1/2" 20 10 20 10

3" 20 10 20 10

4" 20 10 10 10

5" 10 10 10 10

6" 10 10 10 5

8" 10 5 5 5

10" 5 5

12" 5 5

Importers, distributors, and manufacturers of heavy and structural bolting. Large sizes of low carbon, medium carbon, austenitic, and alloy steels available from stock.

Importers and domestic fabricators of sheet gasket material and pipe flange gaskets. Gaskets fabricated for pipe sizes to 144” in rubber, fiber, PTFE, graphite, and spiral wound.

Fabricators of flange isolation kits. Kits available up to 144” pipe size in epoxy glass, phenolic, polyethylene and BoPET.

Accessories for complete systems supplied and organized from engineering technical specifications. Buy American provision for material, manufacture, or substantial transformation available.

Fort Worth * Houston

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Saint Ferrer® Flange Isolation Kit Product CatalogComponents for Flange Insulation and Dielectric Isolation