K-Flex LNG Application Manual

L'ISOLANTE K-FLEX
L'ISOLANTE K-FLEX
LNG apPlications Manual
Via Don Locatelli, 35 - 20040 Roncello (MI) Italy - tel.: +39.039.68241 - fax: +39.039.6824560
e-mail: [email protected] / [email protected]
www.kflex.com

The insulation LNG plants may forsee a multilayer design
according to the specific characteristics and the working
temperatures of the plants that need to be insulated.
In order to establish the correct scale of the insulation,
always refer to the project specifications and to the specific
“K-FLEX IN CLAD Piping Equipment Insulation Specification”
attached to this document.
L’ISOLANTE K-FLEX
indice
TOOLS NEEDED TO CARRY OUT THE INSULATION 4

ACCESSORIES 6
INSTALLATION INSTRUCTIONS 9
PREPARATIONS BEFORE STARTING 10

MULTILAYER INSULATION, PIPES 11
First layer 11
Middle layers 14
Installation K-FLEX IN CLAD covering 15
Pipe supports 16
MULTILAYER INSULATION, SPECIAL PARTS 18
Preformed “T” connection, first layer 18
Making the “T” connection sections on-site from sheets 22
Making the vapour barrier on the “T” connection 24
Preformed elbows: first layer 25
Elbows and “T” connections. Following layers (applies to the two, three or more layer designs) 28
Flanges 32
Insulation of the valves 36
Fixing the K-FLEX IN CLAD covering onto the “T” connection 40
Fixing the K-FLEX IN CLAD covering on flanges 42
Fixing the K-FLEX IN CLAD covering on valves 46
SPECIAL PREFORMED MULTILAYER SECTIONS 50
LIST OF DRAWINGS 53
STRAIGHT PIPE 54
PIPE SUPPORT 55
FLANGE 56
BLIND FLANGE 57
END CAP 58
ELBOW 59
“T” CONNECTION 60
CONCENTRIC REDUCTION 61
TECHNICAL SPECIFICATIONS 63
general principles
1° LNG insulations are all multilayered

2° The first layer is never glued
3° The joints of the first layer always have an expansion joint
4° The first layer is always covered with an aluminium/polyester vapour barrier
5° The first layer does not adhere perfectly to the pipe: an excess of 2-5%
is necessary to allow for thermal contraction of the insulation during use
6° The following layers are installed in the same way as those for traditional
applications for cold (glue and anticondensation tape on all joints and staggering
of the joints between the various layers
tools needed for the job
compass brushes
spatula marker pen

knife-shapening stone scissors ruler knife
scalpel compass to measure chalk sand paper

diameters

accessories
TAPE, COVERING AND AdHesivES

L’ISOLANTE K-FLEX advises using two types of tape: K-FLEX ST
anticondensation tape and K-FLEX ALU AA 130 tape.
ANTICONDENSATION TAPE ALU AA 130 Tape K-FLEX in clad tape

Measurements Self-adhesive joint covering tape Measurements
Thickness mm: 3 in smooth aluminium Thickness: 1 mm
Lengths m: 10, 15 Measurements Length m: 25
Widths mm: 50, 75, 100 Thickness: 30 µ Widths mm: 50, 100
Length m: 50
Widths mm: 50, 75, 1000
alu 5 layer foil K-FLEX IN CLAD covering

Measurements Measurements
Thickness: 80 µ Thickness mm: 1
Length m: 100 Length m: 10
Width mm: 1.000 Width mm: 1.000

INDICATED CONSUMPTION OF 1 LITRE OF ADHESIVE
TUBES glued to the heads glued lengthways
thickness mm 9 every 1.350 m every 150 m
thickness mm 13 every 500 m every 100 m
L'ISOLANTE K-FLEX does not accept responsibility for consumptions that may differ to those indicated above
K-FLEX ADHESIVES
K-FLEX K 420 glue has been specifically designed for use with K-FLEX
elastomeric foam insulation material. The securely bonded surfaces and
joints are resistant to ageing and atmospheric agents and preserve the
technical characteristics of the insulating material.
K 420 ADHESIVE in tins of: 0,26 - 1 - 2,6 litres
marine sealant SPECIAL K-FLEX THINNERS

Marine sealant is suitable for making elastic constructive joints and has Before covering the surfaces to be insulated, it is advisable to clean them
extremely good UV-resistance and ageing properties. thoroughly with the special K-FLEX thinners.
Product is based on Silyl Modified Polymers.
Packaging: cartridges 290 ml 1 LITRE TINS

INSTALLATION INSTRUCTIONS

PreparaTION BEFORE STARTING TO INSULATE
1 2 3 4
1. cleaning the surface to insulate. 3) compensation joints.

Thoroughly degrease the surface to be insulated with the producer’s spe- Prepare a sufficient quantity of mineral fibre compensation joints according
cified thinners to the following indications:
a) prepare several 30 mm thick mineral fibre strips;
2) STAGGERED LAYERS. b) cut sections with the same width as the insulation’s thickness eg. 50 mm
The insulation must be carried out, making sure that the end joints of tubes thickness, (fig. 2).
(preformed up to a diameter of 168 mm) and of sheets (for diameters from c) The mineral fibre strips should each be cut to a width of 50 mm. This
140-170 mm) are always staggered in order to ensure that the edges are material will be used for making the compensation joints, (figs. from 2 - 4).
never aligned. In this way, starting to insulate from the pipe supports (fig.
1) where the sections are already staggered, the next layers are applied with
end joints that are not aligned.
5 6 7 8
4. making the right size tubes from sheets a) Cut a strip of K-FLEX ST elastomeric material of about 100 in width, fig. 5.
The insulation of the pipes can be carried out using preformed tubes, cut b) With the strip, measure the circumference of the pipe to insulate and
out from sheets, or, when working on-site it is possible to use sheets for make a mark on the strip to indicate the correct circumference. Add to this
insulating pipes of large dimensions. Usually preformed insulating tubes measurement an excess of 3% (fig. 6). NB: Gently lay the strip onto the
are used for diameters from 140-170 mm whereas for greater diameters it tube. Do not stretch, avoiding ending up with a section which is too short.
is easier to use sheets cut to size, as indicated further on in the manual, in c) Lay the K-FLEX insulation sheet onto a flat surface and use the previously
order to obtain the desired result, or one can even order the sheet section cut strip to obtain the sheet sections needed to insulate the pipes, (figs.
already prepared for installing. 7-8).
10
MULTILAYER INSULATION, PIPES
FIRST LAYER
9 10 11
1. ApplYING THE FIRST LAYER d) Once the tape is fixed perpendicularly, apply the tape along the complete
a) apply the tube sections, previously cut out of a sheet, onto the pipes. length of the tube to be insulated, over the joint, (fig. 11).
b) Seal the insulation together with 50 mm ALU AA 130 self-adhesive tape, e) Rotate the logitudinal seal downwards, turning the insulation 180° to po-
attaching strips every 30 cm perpendicularly to the cut, (fig. 9). sition the tube’s sealed joint towards the ground.
c) To make sure that the ALU AA 130 tape is correctly placed, press to-
gether the logitudinal edges of the insulation so that they touch and secu-
rely fixdown the tape, (fig. 10).
12 13 14
2. Installing the compensation joints b) It is advisable to install the elasto-

Between each insulated section, add a strip of previously prepared mineral meric material so that they come into
fibres, see pag. 10. contact and then, using force, insert
a) position the strip between the insulated tube sections, (fig. 12). the mineral fibres strip between the
end joints, (figs. 13-14).
11
FIRST LAYER
16 17
3. vapour barrier
a) From a roll of ALU 5 layer foil, cut out a sheet with a width equal to one
and a half times the circumference of the insulated tube, (figs. 16-17).
18 19
b) Apply the sheet of ALU 5 layer foil onto the K-FLEX insulation, securely All the edges of the vapour barrier must be staggered.
fixing it down to obtain a tight fitting cover, (figs. 18-19).
12
FIRST LAYER
20 21
c) It is important to stagger the edges of the insulation and the edges of the
ALU 5 layer foil in order to avoid continuity with the underlying edge. Every
sheet of ALU 5 layer foil should be positioned in such a way as to overlap
the following one by at least 100 mm between one section and another.
d) On both the longitudinal and end joints apply 50 mm ALU AA 130 self-
adhesive tape to fix down the vapour barrier, (figs. 20-21).
13
middle layers
22 23 24 25
Indications for cutting sheets to size 3. Use K-FLEX K-420 adhesive for sealing both the longitudinal and end join-
1. Repeat the procedure described above for carrying out the insulation of ts of both the sheets and tubes, applying the glue with a brush on both the
the following layers, without adding any excess during the preparation of sides to be sealed. Wait until the glue dries before installing the insulation
the sheet sections. material, (figs. 22-24).
2. Take care not to overlap the expansion joints of the following layers. 4. Install the insulation on the tube, taking care to avoid positioning the join-
ts above those of the underlying layer. (first or second layer), (fig.25).
26 27 27a 27b
5. Apply, only on the second layer, 50 mm K-Flex anticondensation tape on 6. For layers applied after the second one, it is not necessary to use (figs.
all the longidudinal and (fig. 26) head joints which were previously glued 27 - 27b) anticondensation tape.
together, (fig. 27).
14
installing the K-FLEX IN CLAD covering
28 29 29 30
1. PreparaTION OF IN-CLAD c) Securely press down the K-FLEX IN CLAD covering along the whole circu-
From a roll of K-FLEX IN CLAD, cut a sheet with the same width as the mference, in order to obtain a tightly fitting cover, fig. 29.
circumference of the insulated tube, adding an excess of roughly 50 mm for d) With a brush, apply K-FLEX K-420 adhesive on both ends in order to
the longitudinal overlap. obtain a perfect seal against water between the covering and the insulation
material, (figs. 30-32).
2. Installation
a) Apply a layer of K-FLEX K-420 glue along the section of the tube to be NB: Take care to stagger the edges of the insulation and the the edges of
covered with K-FLEX IN CLAD. K-FLEX IN CLAD to avoid continuity with the underlying edge.
b) Position the K-FLEX IN CLAD on the area where the glue has been ap- Each sheet of K-FLEX IN CLAD should be positioned in such a way as to
plied and from that point wrap the K-FLEX IN CLAD sheet around the whole overlap the next sheet by at least 50 mm. Use K-FLEX K-420 on both the
section. longitudinal and transverse overlaps.
31 32 33 34
3. Sealing with marine sealant Proceed as follows on all the joints indicated in figures 33 and 34:
In order to obtain a covering with a secure water barrier, use marine sealant
approved by L’ISOLANTE K-FLEX on all the joints: a) with the corect dispensor, spread a layer of marine sealant at least 10 mm
wide, (figs. 33 - 34).
- Between all the longitudinal and transverse overlaps of the K-FLEX IN b) check that there are no breaks in the seal
CLAD covering c) carefully follow the instructions indicated on the tin of sealant and check
- Betwen the pipe supports and the K-FLEX IN CLAD covering the time required to obtain a secure and permanent seal.
- Between the overlaps of the valves, flanges, “T” connections and
terminals
- On the sections of the elbow covered with K-FLEX IN CLAD
- On all the overlaps and K-FLEX IN CLAD joints.
15
pipe supports
35 36 37 38
4.Pipe Supports force in order to achieve a tight fit of the longitudinal shell sections.
For a correct installation of the PU pipe supports, proceed as follows: Position two aluminium sheets under the jack to avoid ruining the supports,
a) On a work surface, position all the shell sections needed for the pipe (fig. 38).
support f) Wrap around the appropriate reinforced fiberglass tape three times in the
b) Apply Foster putty on the edges of the PU “shell” sections, (fig. 35). following three positions, (fig. 39).
c) On the tube, apply an elastic band as shown in figure 36, which will help - On the side of the left jack towards the centre, at about 10 cm
to hold the shells onto the tube. - On the side of the right jack towards the centre, at about 10 cm
d) Apply the support sections one at a time starting from the top and conti- - At the centre of the pipe support
nuing in a clockwise direction, rotating then downwards, (fig. 37). g) Remove both left and right jacks.
e) Use the correct tools at the ends of the pipe support (10 cm from the Proceed in the same way for the following layers taking care to:
right and left edges) to secure the support onto the tube, using sufficient - apply the vapour barrier on the first layer, leaving 100 mm of overlap on
39 40 41 42
each side, and apply 1,5 rotations of ALU 5 layer foil. Finally, seal the vapour laps with K-FLEX K 420 adhesive.
barrier with reinforced fiberglass tape, (fig. 40). - Apply marine sealant to all the joints around the pipe support.
h) For all the following layers (fig. 41) of the pipe support, the vapour bar- - to avoid water infiltrations, cover all the openings around the supporting
rier should be positioned only when the installer has attached the metal collar with marine sealant, (fig. 42).
collars, (fig. 42); afterwards, proceed with the covering as follows:
- Measure the distance between the end of the metal collar and the pipe
support, add 50 mm of excess for the overlap and cut out a strip of K-FLEX
IN CLAD.
- Install this strip, taking care to glue the longitudinal and transverse over-
16
pipe supports
43 44 45 46
Connection between the pipe support and the tube sections K-FLEX IN CLAD covering
a) First layer The pipe supports should be covered externally with K-FLEX IN CLAD. Pro-
On the edges, apply mineral fibre strips as previously carried out for the ceed as follows:
elastomeric material, (fig. 43). Cover everything with the vapour barrier as a) Cut a section of K-FLEX IN CLAD equal to the external circumference of
shown in figure 44. the pipe support, plus 50 mm of longitudinal and transverse excess on all
b) Following layers sides, (fig. 46).
Glue the two ends of the supports to the elastomeric material using K-FLEX
K-420 adhesive.
Only on the second layer, apply 50 mm K-FLEX anticondensation tape on all
the glued joints, (fig. 45). In a three layer installation, on the third layer, it is
not necessary to apply anticondensation tape.
47 48 49 50
b) Wrap the covering around the pipe support, (fig. 47). d) Join together the areas to be glued and apply enough force to ensure a
c) Apply K-420 glue on both the longitudinal and transverse overlaps of the perfect sealing, (fig. 49).
K-FLEX IN CLAD covering and also onto the areas below onto which the
overlaps will be glued, (fig. 48). Coverings
On both sides of all joints, apply a 10 mm layer of marine sealant, (fig.
50).
17
MULTILAYER INSULATION, special parts
preformed “T” connections, 1° layer
51 52 53 54
5. “T” connections a) On the tube, apply the single precut “T” connection sections (fig. 51),
first layer with “T” connection in sections ready for installing fixing them together with 50 mm ALU AA 130 self-adhesive tape along all
The “T” connection is made of two pieces ready for installation as shown the joints (figs. 52, 53, 54). NB: first install the horizontal section (figs. 52
in figure 51. As previously indicated for straight sections, the installation and above) followed by the vertical one (fig. 64 and following).
should be carried out following the multilayer design. The first layer must b) ALU AA 130 self-adhesive tape should be applied as shown in figures
never be glued; ALU AA 130 tape will be used to fix the “T” connection 55 to 58.
sections to the pipe. Proceed as follows.
55 56 57 58
NB: The ALU AA 130 tape should be applied both longitudinaly and tran- NB: The prepared “T” connection sections needed for the installation are
sversely over the joints, as shown in figures 52 to 58. already supplied with a 3% excess. During the installation, this excess
should be maintained. Therefore only seal down what is necessary.
18
preformed “T” connections, 1° layer
59 60
d) With controlled pressure, insert the mineral fibre strips into the joints as
shown in figure 59.
e) When this operation is complete, the “T” connection should now appear
as shown in figure 60.
19
making the “t” connection sections on-site from sheets
61 62 63 64
The “T” connection sections can be easily made directly on-site by cutting - Transfer the measurements onto a K-FLEX ST sheet as indicated by the red
them out of a section of K-FLEX ST sheet. They should be made in two arrow in figure 75 for preparing the length.
sections, a horizontal and vertical one, (fig. 51). - Measure the diameter of the “T” connection, (fig. 62).
Proceed as follows. - Transfer the measurements of the diameter onto a ruler, (fig. 63).
a) Horizontal section - Divide the measurement by 2 (fig. 64) to obtain the radius needed to trace
Prepare a strip of K-FLEX ST elastomeric material about 100 mm wide, with two semi-circles with a compass, (fig. 65).
the same thickness as the insulation which will be used, in order to take
the measurements of the circumference, fig. 61. Do not stretch the strip,
avoiding creating a section that could be too short. Finally, add an excess
of 3%.
65 66 67 68
- The width of the sheet (green arrow in fig. 65) should be equal to 3 times - Once the two semi-circles have been marked out with the point of a com-
that of the measured radius in figure 74. Whereas the length, as previously pass (fig. 67), start to cut them out along the lines with a sharp knife, (fig.
indicated, is the same as the circumference of the “T” connection section, 68).
as indicated in figure 66.
20
69 70 71 72
- Apply the horizontal section of the “T” connection onto the pipe, (fig.
69).
- Fix the horizontal section together using ALU AA 130 tape as indicated in
figures 70 to 72.
73 74 75 76
Preparing the vertical section - Divide a second K-FLEX ST sheet into four equal sections, using the
To prepare the vertical section of the “T” connection, proceed as follows: same method as indicated in figure 61. Draw a line parallel to the edge.
- Take the measurements of the coupling arm section by resting the cut The distance from the edge must be equal to that of the difference in height
sheet on it to use as a basis for measuring, (fig. 73). measured in figure 85. This line is needed to obtain the intersecting point
with the three previously drawn vertical lines to use as the center for the
following circles, (figs. 86 - 93).
21
78 79 80 81
- At this point, with the help of a metal ruler, trace 4 sections as indicated - With a white felt pen, draw a median line which exactly divides in two the
in figures 78 and 79. previously drawn section, (fig. 80).
- Finally draw the curves as indicated in figures 81 and 82.
82 83
Fig.93 84
Fig.94 Fig.95
85
- cut out the final shape following the lines, (fig. 83). - Measure the distance between the horizontal “T” connection section and
the next already installed section, (fig. 84).
Transfer the measurements onto the sheet (fig. 85) and cut out the horizon-
tal section of the “T” connection, which is now ready to be installed.
22
86 87 88 89
- Install the section onto the pipe, fixing it together with 50 mm ALU AA 130 NB: The ALU AA 130 tape should be applied both transversely (figure 103),
self-adhesive tape, as indicated in figures 86 to 90. and longitudinaly to the cut as shown in figure 90.
90 105 91 92
- Apply, in the intersection between one sheet and another, a 30 mm thick NB: Bearing in mind the function of these strips (to compensate for the con-
strip of mineral wool; with the same thickness as the insulation which will traction of the elastomeric sheet), it is advisable to install the elastomeric
be used. material so that they come into contact, and then, using force, open them
- Proceed to cut a few strips of mineral fibre as indicated in figure 105 and apart to allow enough space for the wool.
previously on page 20, and insert them between the intersections as seen
in figures 91 and 92.
23
APPLYING the vapour barrier on the “T” connection
93 94 95 96
Prefabricated VAPOUR BARRIER The final result will result in a perfect vapour barrier, (fig. 100).
- On the first insulated layer, apply the prefabricated, ALU 5 layer foil sec-
tions of the “T” connection, (fig. 93).
- Apply the vapour barrier securely, in order to obtain a tight fitting cover
which compensates for the 3% of excess previously added to the insulation,
(figs. 91 - 97).
- Cover each overlap with 50 mm ALU AA 130 self-adhesive tape, (figs. 95
- 96 - 98 - 99).
97 98 99 100
making the vapour barrier on-site Every sheet of ALU 5 layer foil should be positioned in such a way as to
Prepare the sections which will be applied to the insulation by cutting them overlap the following sheet by at least 100 mm.
out of a sheet of ALU 5 layer foil, following the instructions indicated in On both the longitudinal and tranverse overlaps, 50 mm ALU AA 130 self-
the previous pages for making the “T” connection with K-FLEX insulation. adhesive tape should be used.
Apply each sheet of 5 layer aluminium foil onto the insulation, fixing them
down securely in order to obtain a tightly fitting cover and to compensate
for the 3% of excess previously added to the insulation. Take care to stag-
ger the edges of the insulation and the edges of the ALU 5 layer foil sheet to
avoid continuity with the underlying edge.
24
preformed elbows: first layer
1 2 3
a) first layer: elbow in sections - On the pipe, apply the single precut elbow sections previously cut out of
- The first layer of the elbows must be constructed using precut sections, a sheet of K-FLEX ST, closing them together with 50 mm ALU AA 130 self-
ready to be installed, (fig. 1). adhesive tape along all the joints, (figs. 2 - 3).
4 5 6 7
- Repeat the operation and proceed to apply all the elbow sections. - Continue to apply ALU AA 130 self-adhesive tape to close all the sections,
NB: The elbow sections which have a straight side, the ones at the start and as shown in figures 4- 5- 6- 7.
at the end, can be used in a specular way, (fig. 1).
25
8 9
b) compensation joints NB: When this operation is complete, the elbow should resemble the photo
- Insert a mineral fibre strip (see previous pages for indications on how to in figs. 9 (detail) and 10 (complete elbow).
make mineral wool strips) between each section of the elbow.
10 Fig.20 11
Fig.20 12
c) vapour barrier - Attach them securely, in order to obtain a tight fitting cover and close each
- On the insulated first layer, apply the prefabricated elbow sections in ALU section with ALU AA 130 self-adhesive tape, (fig. 12).
5 layer foil (fig. 11), taking care to overlap each segment over the previous
one by at least 50 mm.
26
13 14 15 16
- Repeat the previously indicated operations for all the elbow sections, (figs. Cover each overlap with 50 mm ALU AA 130 self-adhesive tape, (fig. 16).
20 and 21).
27
elbows and “t” connections:

following layers
17 18 19
elbows b) Apply K-FLEX K 420 glue on the cut edges and wait until the glue is
With preformed elbows: almost dry, (fig. 21).
a) Cut the preformed elbow along the lower spine, (figs. 18 - 19).
20 21 22 23
c) Mount the elbow onto the tube, (fig. 20). e) Apply K-Flex K-420 glue on both the lateral edges and wait until the glue
d) Starting from the two extremities, glue the joints together. Make sure that is almost dry, (fig. 23).
both sides are well glued, also internally, (fig. 22).
28

following layers
23 24 25 26
f) Next, apply 50 mm K-FLEX anticondensation tape over all the glued joints, Preparing the elbows on-site from sheets
(figs. 24 - 25). - First of all, measure the internal radius of the curve using a ruler with
another ruler lying perpendicular to it, as shown in figure 26.
27 28 29 30
- Using a compass, mark out the outline of the internal radius on the K-FLEX - Cut the sheet accurately along the arc of the circle, (fig. 29).
sheet, using the corner of the square marked out on the insulating material - Place the section obtained on the reverse side of another sheet and use it
as the axis, (fig. 27). as a template to cut out a second, mirror image section, (fig. 30).
- measure the exact circumference of the pipe using a strip of K-FLEX ST - Allow the glue to dry and stick the edges together, starting from the two
sheet of the correct thickness and divide the circumference by two, and extremities.
mark the middle of the strip accordingly. - Finally, install the elbow and follow the same procedures already indicated
- Add the outer radius to the measurement of the inner radius and, using for preformed elbows, (figs. 23 - 24 - 25).
the same axis, mark out a semicircle onto the sheet with the compass, (fig.
28).
29

following layers
Fig.31
31 Fig.32
32 33 34
Installation of the 3° elbow layer Installation of the second “T” CONNECTION layer
Proceed to install the third layer of the elbow as previously indicated for - The installation of the second “T” connection layer must be carried out
the second layer (both for preformed elbows and elbows cut out of sheets with the same procedure as previously indicated on pages 19 and 25, both
on -site). for preformed “T” connections and for those made directly on-site from
NB: In the third layer do not use K-FLEX ST anticondensation tape. It is only sheets.
necessary to:
- Install the elbow
- Glue the joints with K-FLEX K-420 adhesive, (figs. 31 - 32).
35 36 37 38
- However, there are certain aspects to take into consideration: - Apply ST anticondensation tape over all the joints as indicated in figures
1. K-FLEX K-420 glue, which was not used on the first layer, must be used 37 and 38.
on all the joints of the ”T” connection. At this point the “T” connection is ready to be covered with K-FLEX IN
CLAD, or in the case of the three layer design, the third elastomeric layer
can now be installed.
The procedure to follow for the third elastomeric layer is exactly the same
as that indicated for the second layer except that ST anticondensation tape
should not be applied.
30

following layers
39 40 41
Application of the third “T” CONNECTION layer

- As previously indicated, the application of the third layer differs from that
of the previous one in as much as it is not necessary to apply ST anti-
condensation tape on the joints. The photos from 39 to 41 show the “T”
connection insulated with 3 layers.
31
flanges
42 43 44 45
installation of the first layer of the flange cover Use Alu AA 130 tape to secure the ring onto the flange, (fig. 45).
- Measure the pipes’ circumference. Use the measurements of the two dia- Complete the insulation of the tubes on the left and right sides of the flange
meters to calculate the respective inner and outer radii, (fig. 42). as indicated in the above figures, (figs 46 - 47).
- After calculating the two radii, mark out the inner and outer circumferen-
ces of the rings on two separate squares of K-FLEX ST sheet.
- Attaching a sharp blade to the tip of the compass allows the first incision
to be made so that a knife can then be used to cut out the ring. However, a
knife alone can give acceptable results, (fig. 43).
Cut the rings out and make an opening on one side to attach them around
the pipes, (fig. 44).
46 47 48 49
- Repeat the same operation for the other side of the flange, (fig. 48). - Measure the distance between the two rings, including the thickness of the
- Apply a strip of mineral fibres between the rubber ring and the pipe as insulating material, (fig. 49).
shown in figures 48 - 49.
32
flanges
50 51 52
- Use a strip of K-FLEX ST sheet of the same thickness to measure the - Mount it around the rings and tape together the edges, (fig. 51).
circumference of the insulating rings, (figs. 50 - 51). - Fix it securely with Alu AA 130 tape as indicated in figure 52.
- Transfer the measurements onto a K-FLEX sheet to obtain the outline of
the sleeve that will complete the flange’s insulation.
53 54
installing the vapour barrier

Measure the circumference of the insulated flange and the tube section,
(figs. 53-54).
33
flanges
55 56 57 .58
- Transfer the measurements onto a sheet of ALU 5 layer foil using a com- - Make perpendicular internal and external cuts with a pair of scissors, (fig.
pass as shown in figure 55. 57).
- With the compass, add 5 cm for the overlap and draw the circle, (fig. - Make a cut as indicated in figure 58 and apply the vapour barrier onto the
56). flange as shown in figure 59.
59 60 61
- Repeat the same operation for the other side of the flange. - Finish the vapour barrier with Alu AA 130 tape as indicated in figure 61.
- Seal everything using Alu AA 130 tape, (fig. 60).
34
flanges
62 63 64 65
SECOND FlangE LAYER - Apply K-Flex ST anticondensation tape over all the joints, (figs. 65 - 66).
- Repeat the operations previously carried out for the first layer to create the
second layer of the flange cover, (fig. 62).
- Use K-FLEX K-420 glue to seal together the second layer of the flange
cover, (figs. 63 - 64).
66 66 67 68
- Once the ST anticondensation tape has been applied, the insulation of the insulation of the 3° FLANGe layer
flange should appear as in figure 66. To apply the third insulation layer on the flange, follow the same procedure
indicated for the application of the second layer. However in this case it is
not necessary to apply K-FLEX ST anticondensation tape. To seal the flange
cover, as indicated for the second layer, use K-FLEX K-420 glue.
35
insulation of the valve
69 70 71 72
insulation of the valves - Carefully cut out the rings.

- Measure the diameter of the pipes and the flanges. Use these measure- - Make an opening so that they can be fitted over the pipes.
ments to calculate the relevant radii, (fig. 70). - Place a ring on the outside of the valve, (fig. 72).
- After calculating the radii, mark out the respective inner and outer circu-
mferences on two separate squares of K-FLEX ST sheet of the same thick-
ness, (fig. 71).
73 .74 75 76
- Fix the ring onto the valve with AA 130 tape as shown in figure 73 - Next, calculate the shape of the disc for the top of the flange.
- Apply a strip of mineral fibre between the ring and the flange, (fig. 74). - Measure the circumference of the supporting flange and the form of the
- Apply a strip of K-FLEX ST sheet around the top part of the flange as indi- face plate around which the disc must fit. Mark out the measurements on a
cated in figure 74 and fix it with ALU AA 130 tape. section of of K-FLEX ST sheet and cut the disc out, (figs. 75 - 76 - 77).
36
77 78 79 80
- Make an opening so that the disc can be fitted over the face plate, (fig. - Draw the outline of the sleeve section measurements onto a sheet of K-
78). FLEX ST sheet and draw a line down the middle.
- Position the disc over the face plate. - Measure the diameter of the stopcock housing.
- Divide the diameter by two to obtain the radius. Place the compass at the
end of the sleeve’s center line and draw a semicircle at each end, (fig. 80).
81 82 83 84
- If there are any imperfections along the cut edges, smooth them out so APPLYING THE VAPOUR BARRIER ONTO THE valve COVER
that they precisely bond together. FIRST LAYER
- Fix the valve’s cover with Alu AA 130 tape, (fig.82). The insulation of the valve on the first layer should be completed with the
vapour barrier made from ALU 5 layer foil. As already indicated in the pre-
vious sections for making the vapour barrier, proceed as follows:
- measure the internal and external diameters of the sides of the valve, (fig.
83).
- transfer these measurements onto a sheet of ALU 5 layer foil (see figures
55 to 58 on page 34) and cut out the covers in aluminium as shown in
figure 84.
37
85 86 87 88
- Position the previously prepared rings onto the left and right side and also - take the measurement as indicated in figure 87 in order to prepare the
onto the cover of the valve, (figs. 85 - 86). second section of the vapour barrier.
- transfer the measurements onto a sheet of ALU 5 layer foil and cut out the
shape using a pair of scissors.
99 100 101
- Once this section of the vapour barrier has been cut out, it should have the - Fix this section of the vapour barrier onto the valve with ALU AA 130 tape,
same shape as shown in figure 99. (figs. 100 - 101).
- Finally proceed to install this section onto the valve as shown in figure
100.
38
102 103 104 105
- Proceed to insulate the right and left tube sections of the valve with the - From a sheet of ALU 5 layer foil, cut out this section of the vapour barrier
vapour barrier (already insulated with the first layer of K-FLEX ST). and position it onto the valve, (figs. 104 - 105).
- Measure the valve section which still needs to be covered with the vapour - Fix everything together with ALU AA 130 tape, (fig. 106).
barrier, (fig. 103).
106 107 108 109
39
FIXING THE K-FLEX IN CLAD COVERING ONTO THE “t” CONNECTION
1 2 3 4
fixing the K-FLEX IN CLAD covering c) Apply K-FLEX K 420 glue, as shown in figures 20 onwards, both to the
onto the “t” connection elastomeric material and the K-FLEX IN CLAD covering.
a) Thoroughly degrease each section of the prefabricated K-FLEX IN CLAD
“T” connection with the correct thinners.
b) The “T” connections are made in three pieces which should be directly
applied onto the elastomeric sections. First install the main section of the
“T” connection followed by the coupling sections.
5 6 7 8
d) Once the K-FLEX IN CLAD covering is positioned onto the insulation, e) Finally, press the overlaps down with force to make sure that both surfa-
carefully seal all the overlaps with K-FLEX K 420 glue, (fig. 6). ces firmly adhere together, (fig. 8).
40
FIXING THE K-FLEX IN CLAD COVERING ONTO THE “t” CONNECTION
9 10 11 12
f) Proceed to apply the K-FLEX IN CLAD covering onto the coupling, repea- g) Finally, spread glue over all the joints, (fig. 11).
ting the same procedure as before, (figs. 9 and 10). e) The “T” connection is now ready to be sealed with marine sealant, (fig.
12).
13 14 15 16
applying marine sealant:

a) Apply a 10 mm layer of marine sealant on both sides of all the joints c) Marine sealant should be applied to all joints as can be seen in figure
b) Proceed carefully as indicated in figures 13 - 14. 16.
41
fixing the K-FLEX IN CLAD COVERING on the FLANGE
17 18 19 20
APPLYING THE K-FLEX IN CLAD COVERING ONTO THE FLANGE c) using a sharp knife, cut around the furthest circle to obtain the disc.
a) measure the internal and external diameters of the flange, (fig. 17).
b) using a compass, mark out the internal and external measurements onto
a sheet of K-FLEX IN CLAD. Add an excess of 5 cm to the external diameter
and trace a third circle, (fig. 18).
18 19 20 21
d) Make external and internal fringes on the disk as indicated in figures 19 h) Use K-FLEX K-420 glue to fix the disk onto the flange, (figs. 20 - 21).
and 20
e) The disk is now ready to be mounted onto the flange, (fig. 18).
f) Repeat the same operation to cover the other side of the flange.
g) Make an opening cut on the disk and slot it onto the flange, (fig.19).
42
22 23 24 25
i) tightly close the fringes of the disc, which have already been glued with k) Proceed by measuring the central section of the flange, (fig. 24).
K-FLEX K-420, in order to obtain a perfect grip. l) Transfer the measurements onto a sheet of K-FLEX IN CLAD and cut out
j) When installed, the disk should appear as in figure 23. the required section, (fig. 25).
26 27 28 29
m) spread K-FLEX K-420 glue on the elastomeric material and wait until it n) Place the previously prepared strip of K-FLEX IN CLAD onto the flange.
is almost dry. o) To correctly attach the K-FLEX IN CLAD sheet, use K-FLEX K-420 glue
and allow it to almost dry before sealing down both edges .
43
30 31
applying marine sealant:

a) Spread a 10 mm layer of marine sealant over both sides of all joints.
b) Proceed carefully as indicated in figures 38 - 40 of the following page.
44
fixing the K-FLEX IN CLAD COVERING on the elbows
32 33 34 35
APPLYING K-FLEX IN CLAD COVERING ONTO THE ELBOWS c) The elbow segments should be fixed onto the throat with (figs.33 and
a) Apply the preformed K-FLEX IN CLAD elbow segments onto the elbow by 34) K-FLEX K-420 glue.
sealing them onto the elastomeric material with K-FLEX K- 420 glue.
b) After appling the K-FLEX K-420 glue, wait until it is almost dry before
fixing the segments onto the elbow.
38 39 40
applying:
b) Proceed carefully as indicated in figures 38 - 40.
45
fixing the K-FLEX IN CLAD COVERING on the valve
1 2 3
IN-CLAD covering: Valves c) Using the difference in the two lengths as a radius, draw circles around
To fix the K-FLEX IN CLAD covering on valves, proceed as follows: the ends of the lines. Using the arcs of the circles, draw a continuous line
a) Measure the distance between the disc and the existing lagging at its linking them up, as illustrated in figure 3.
nearest and furthest point, (fig. 1).
b) Mark the two different measurements on the dividing lines of the tracing,
as illustrated, then draw the intersecting lines from one extremity of the
shape to the other, (fig. 2).
4 5 6 7
d) Add a third line which will be used as a guide to make the fringes, (fig. e) Proceed by making longitudinal cuts as shown in figure 6.
5). f) Apply the K-FLEX IN CLAD covering as shown in figures 7 and 8.
46
8 9 10 11
g) Use K-FLEX K-420 glue to fix the K-FLEX IN CLAD covering onto the PREPARING K-FLEX THE IN CLAd SIDE DISKS OF THE VALVE
insulation. a) Measure the internal and external diameters of the valve
h) Apply the glue onto both the K-FLEX IN CLAD covering and the insulation b) using a compass, mark out the measurements of both the internal and
with a brush, (fig. 9). external diameters onto a sheet of K-FLEX IN CLAD. Add 5 cm to the to the
external diameter and trace a third circle which will be used for the overlap,
NB: Wait until the glue is almost dry before proceeding with the installa- (fig. 11).
tion.
i) Using pressure, firmly seal down all the previously prepared fringes.
12 13 14 15
c) using a sharp knife, cut out around the external circumference to obtain h) Use K-FLEX K-420 glue to seal the disc onto the valve, (fig. 15).
the disk.
d) Make internal and external fringes in the disk as indicated in figures 12
and 13.
e) The disk is now ready to be mounted onto the valve, (fig. 14).
f) Repeat the operation to cover the other side of the valve.
g) Make an opening cut in the disk and slot it onto the valve.
47
16 17 18 19
i) Using pressure, fix down the disk fringes, previously spread with K-FLEX d) On the previously prepared K-FLEX IN CLAD disk, carefully draw out the
K-420 glue, in order to obtain a perfect mechanical grip. protruding parts of the valve’s cover, (figs. 18 - 19).
j) When the disk is installed, it should appear as in figure 16.
K-FLEX IN CLAD valve cover

Now proceed to make the valve cover with K-FLEX IN CLAD.
a) with a compass, take the measurements of the valve’s diameter
b) transfer the measurements onto a sheet of K-FLEX IN CLAD.
c) cut the disc as shown in figure 17.
20 21 22 23
e) With a sharp knife cut out the shapes and make an opening cut, (figs. f) proceed to install the disk, sealing it onto the valve with K-FLEX K-420
20 - 21). glue.
48
24 25 26 27
g) proceed by spreading K-FLEX K 420 glue over all the valve’s K-FLEX IN h) Prepare a strip of K-FLEX IN CLAD sheet to apply around the valve’s
CLAD joints, (figs. 24 - 25 - 26). circumference as illustrated in figure 27.
28 29 30 20
i) Using K-FLX K-420 glue, seal the K-FLEX IN CLAD strip onto the valve. applying marine sealant
b) Proceed carefully as indicated in figure 20.
49
SPECIAL preformed MULTILAYER sections
installing elbows, “t” connections, flanges and valves
50
PREFORMED “T” CONNECTION PREFORMED ELBOW PREFORMED FLANGE
The special multilayer preformed sections must be installed in the following way
1) Open the sections

2) Install the first layer
3) Install the vapour barrier
4) Install the second layer using ST self-adhesive anticondensation tape
5) Install the third layer
6) Install the K-FLEX IN CLAD covering
7) Apply marine sealant over all the joints
51
52
list of drawings
53
54
55
56
57
58
59
60
61
62
tecHnicAL SPECIFICATIONS
63
TECHNICAL SPECIFICATIONS
www.kflex.com
All technical documentation in electronic format can
be found at the L’ISOLANTE K-FLEX website in our
online data-base* at:
www.kflex.com, by clicking on the voice
“Download area” in the menu.
*It is necessary to register on the “Download area”

page to receive your password. This will allow you
to enter into our on-line database
L’ISOLANTE K-FLEX
64
L'ISOLANTE K-FLEX
L'ISOLANTE K-FLEX
Via Don Locatelli, 35 - 20040 Roncello (MI) Italy - tel.: +39.039.68241 - fax: +39.039.6824560
e-mail: [email protected] / [email protected]
www.kflex.com

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L'ISOLANTE K-FLEX

LNG apPlications Manual

TOOLS NEEDED TO CARRY OUT THE INSULATION 4

PREPARATIONS BEFORE STARTING 10

1° LNG insulations are all multilayered

spatula marker pen

scalpel compass to measure chalk sand paper

TAPE, COVERING AND AdHesivES

ANTICONDENSATION TAPE ALU AA 130 Tape K-FLEX in clad tape

alu 5 layer foil K-FLEX IN CLAD covering

K 420 ADHESIVE in tins of: 0,26 - 1 - 2,6 litres

marine sealant SPECIAL K-FLEX THINNERS

Packaging: cartridges 290 ml 1 LITRE TINS

1. cleaning the surface to insulate. 3) compensation joints.

2. Installing the compensation joints b) It is advisable to install the elasto-

making the “t” connection sections on-site from sheets

making the “t” connection sections on-site from sheets

making the “t” connection sections on-site from sheets

making the “t” connection sections on-site from sheets

APPLYING the vapour barrier on the “T” connection

preformed elbows: first layer

elbows and “t” connections:

elbows and “t” connections:

elbows and “t” connections:

elbows and “t” connections:

Application of the third “T” CONNECTION layer

installing the vapour barrier

insulation of the valves - Carefully cut out the rings.

102 103 104 105

106 107 108 109

applying marine sealant:

applying marine sealant:

fixing the K-FLEX IN CLAD COVERING on the valve

K-FLEX IN CLAD valve cover

1) Open the sections

*It is necessary to register on the “Download area”

LNG apPlications Manual

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