(((@ Research Centre MAT. TECH. REPORT Porsgrunn, Classification: Internal iis HAE Nitric acid plants Gaskets/packings in the top flange in the burners Aathorey ‘Mette Charlotte Roland 1997-09-29 97R_EHILDOC To: 1613 5B HNO; PNT-members, see p. 2 R76165.300 ‘MM:(VN) ‘Arch. per:_Permanent Copy: Keyword Distribution, see p. 2 PAKNING ‘A. Olsen, HRE SALPETERSYRE Reg ach. FORBRENNINGSOVN Rie dy Benny Srishal 26.556 8& creases Apo aslaat ai ‘Guidelines for approval are desctived in fe Rasearch Ganira Qualiy Handbook (ARETT) ‘Summary/Conclusion: The report gives a summary of gaskets used at the top flange in the ammonia burners in the nitric acid plants of Norsk Hydro. The summary is based on a questionnaire sent out earlier and additional information added later. The types and materials of these gaskets are discussed shortly, and applicable flange groove temperatures - which are the main base for selecting gaskets ~ are given, Finally, a detailed procedure for a system used in the nitric acid plants in Porsgrunn is given, as it works well and is a cheap solution. The best solution for large diameter double flanged burners is to use welding, The second best is to use a braided graphite packing with particle filling (e.g.graphite particles). For smaller diameters, metal jacketed or spiral wound gaskets with grahpite filling should function wellInternal Research Centre Page 2 0f5 To: Copy: Michel Pottier, Brussels Bjarne Jensen, B.17, HPI ‘Torleif Nilsen, Glomtfjord Bo Andersson, Képing Karl Olsson, Landskrona Tom Grundy, Immingham Wolfgang Wolff, Rostock Henri Lambotte, Sluiskil Jean-Marc Marroc, Ambes Philippe Chaboche, Montoir Jean Lue Laroche, Pardies Martino Bassetti, Ravenna Luciano Diomei, Terni Bob Banks, Maitland @ystein Nirisen, HRE Bernt Swensen, HRE Tom Hallan Neringsparken G. Kongshaug, Neringsparken Halvor @ien, HRE Arne O. Egner, HRE Mette Roland, HRE Rune Ingels, HRE Ame Anundskiis, HRE K. Harg, HRE (f.p.) Miv:(VINVS7R_EHT.DOC22 23 24 25 Internal Research Centre Page 3 of 5 Introduction Two years ago a questionnaire regarding gaskets in the nitric acid plants was distributed. The response was not overwhelming, but lately some more information has been gathered. As the main flange (top flange) gasket seems to be the main problem, mainly when asbestos is substituted by other materials, the work has been focused on gaskets for this application, Types of gaskets being used General ‘The information regarding the main flange gasket is given in a tabular form, with - when known - type of gasket, gasket producer, and costs, see Appendix 1. The latter could be of interest, as there can be large differences in costs involved with changing gaskets. The information is sorted with regard to temperature, pressure, gauze diameter and type of groove. Material The materials most used, are glassfiber, graphite and asbestos. Ceramic fibres are used, and these can consist of e.g. Al- and/or Si-fibres. The gaskets are mainly braided, but also sheet and twisted gaskets are used, Braiding There are different types of braiding. One braided graphite packing from producer A might work well, while braided graphite fibre from producer B leaks. This is partially/mainly due to differences in the braiding. The braiding can consist of loose fibres or coarse threads with a braided stocking around, it can be braided all the way through, and the braided pattern itself can vary. Asbestos The advantage of the asbestos gasket is not the high temperature resistance - this is, not needed for the top flange - but its efficient behaviour regarding bad tongue/ groove flange fittings. This is due to the fibres itself being of different sizes, and after tightening some fibres will still be "loose", and not compressed all the way. Temperatures ‘The difference in temperature between the outer diameter of the flange and the tongue is in the order of 100 4/- 50 degrees for the "single" flange systems. This is not the case for the mid flange in the double flange system, which have a temperature which varies in relation to the top and the lower flange. As can be seen in the table, the temperatures at the gasket groove are seldom above 300 C, thus glass fibre can be used (service temp. = 400 -700 °C, depending on type of glass used) . The graphite fibre can be used up to about 400 °C in this environment. MMeVNyS7R_EHS.006Internal Research Centre Page 4 of 5 The flange temperature can be measured by surface thermometer, while "laser" or thermography can be used for the tongue if the gap is wide enough (or a thermo couple can be mounted during the next gauze change). Solution in SS2 and SS3, Porsgrunn The Porsgrunn solution consists of a combination af a braided glassfibre packing and a sealing substance, Permatex ("Form-a-gasket"). It might not work everywhere, but it is described in some detail in Appendix 2, as itis a simple and rather cheap solution (approximately 1000 NOK/ourner). The design in the vicinity of the flange in SS2 and $S3 is given in Appendix 3 to make comparison with other burners possible when judging if the solution could be applicable elsewhere. ‘The tongue temperature in SS3 varies between 200-250 degrees, and the temperatures of SS2 is expected to be lower, as the flange temperature is about 80 degrees lower. This system is replaced at every gauze change, which is approximately twice a year. Re-tightening during shut-downs is not necessary. There is no reason why this solution can not have a longer service life if the flange is not opened, but for how long this can be, is difficult to say. Double flange gaskets On the mixed gas side of these burners, the same system as mentioned above could be used. On the NO,, side however, the conditions are worse. During normal operation the gasket temperature should be less than 350 °C based on information recieved. If a leak occurs, the temperature will rise to 800-900 °C, and asbestos will decompose, only it might take some time. For smaller diameters, metal jacketed or spiral wound gaskets with graphite filler can be used (the spiral wound has a temperature limit of 400 °C). For larger diameters these will not function due to larger deformations in the flange. The best solution for these is to use welding instead. The second best is to use a braided graphite packing with particle filling (e.g. graphite particles), provided the gasket temperature is 400°C or below. This will seal well until an eventual leak occurs. Ceramic fibres can withstand these high temperatures, but will not seal properly. Recommendation Itis recommended to try the Porsgrunn method, as it works well and is a cheap solution. There are no indications so far that it should not function well in the other burners in Hydro. MM:(VINV7R_EH1.D00Internal Research Centro Page 5 of 5 Regarding the double flanged burmers, the best solution (which is on its way for two of the burners) is to either weld or have a new design to avoid the lower gasket. If this can not be avoided, a braided graphite packing with filler particles is recommended for the larger diameters. For smaller diameters, metal jacketed or spiral wound (up to 400 °C) gaskets with graphite filling can function well. Acknowledgement Many thanks to Mr, Arild Olsen who has provided the expertise in the field of gaskets. Porsgrunn, 1997-09-29 nts, Petal Mette C. Roland MM:(VNV97R_EH1.006Internal Appendix 1 Research Centre 2 __Page tof 2 || Fiange temperature (deg. C) = 200 Shallow groove In 881, Porsgrunn [Gasket type Fibertrax rope (glass fibre) Gauze diameter=2.1m [Gasket producer _____*Elof Hanson* [Cost xr/em2_ 18202 30 NOK/m, 018=24 NOKim Flange temperature deg. C) = 300 In $1, Porsgrunn [Gasket ype Fibertrax rope (glass fibre) *Elof Hanson 1920= 30 NOK/m, 615=24NOKin Fiberfrax rope (glass fibre) _ *Elof Hanson* Gauze ciameter=2.1m | Gasket producer [cost wimveme Flange temperature (dog. ©) = 400 In $S1, Poregrunn [Gasket ype Gauze diameter=2.1m [Gasket producer [cost wnvema 220= 30 NOK/m, 015=24 NOK/m faaeaarel 1nge temperature (deg. C) = 120 | Shaiow groove Grooveltounge [Pressure = 5-6 bara_| Groovertounge Flange temperature (deg. C) = 200 In $83, Porsgrunn, \Gasket type Braided glass fibre impregnated with Permatex. | In Landskrona [Gasket type bre *Hepalstos" (60x3.2 mm) |Gasket producer _ “Elof Hanson" | (Cost sdm/em2 | as9 SEK tora set Flange temperature (deg. C) In Rostock [Gasket ype [Square PTFE/graphite “Thermotlon * 6232 TR, dry| Gauze diameter = 8m —_|Gasket producer (Cost »im/em2___| Approximately 2400 DM for each burner Flange temperature (deg. C) = 220 F. Burgman, Dichtungswerk GmbH &Co__| In Montoir (Gasket type T ‘Asbestos-elastomer-graphite’) Gauze diameter=4.3m (Gasket producer _| Trouvay Cajyin _| [Cost x/m/om2 al |Comments: |) re-tigthened during service Flange temperature (deg. C) = 120 In $82, Porsgrunn (Gasket type Gauze diameter=4.0m | Gasket pr (Cost_xm/em2 Gauze dameier=45m [Gasket producer C.Bugge a /Loctte Norgo | __ NOK 1000 per burner InAmbes (Gasket ype “Asbestos Feriam 73430 Gauze dameter=47m (Gasket producer “Athis do Lome -| cost xiniem 2 In Sis [casket type | Braked graphite tres with Incone reinforcement Gauze diameter = 4.8m MNL(VNyO7R_EH1.DOC |Gasket producer | (Cost adm/ema “Beaded gla be impregnated with Pam 'C Bugge a. / Lect Norge ____Less than NOK 1000 per burner Brand: Carrara GR 8807, producer: ARS __NLG 18,000 per bumerResearch Centre Internal ‘Appendix 1 Page 2 of 2 Pressure = §-6 bara lange temperature (deg. C) = 250 In Ravenna, mixed gas side *) Gauze diameter = 1.3m In Ravenna, mixed gas side *) Gauze diameter = 4.2 m In Ravenna, NOX si Gauze diameter 2m In Immingham, *) Gauze diameter = 4.6 m Flan, perature (deg. C) In Ravenna, NOX side *) Gauze diameter = 1.3 m [Gasket type ICost_sdmvem2 [Gasket producer | Mixed gas side: graphite gaskets |Gasket type [Cost xnvem2 |Gasket producer [Gasket type \Gasket producer NA. [Cost [a NA: (Gasket type Exelsior 1500 (asbestos)+Pilotgraph 4040") |Comment \Gasket producer ‘Supplier: Beldam Crossley It. (Cost snvema “All plants have e. dou [Gasket producer —_————_" graphite ribbon [__ Spiralwound gasket with cerar 1 2 | *) Ravenna has a double flange system [Presoue = 8:11 bara | Flange lonporalu (a. 0)= 120 Grooveltounge In Maitland Gauze diameter = 1 - 1.1m MM:(VINV7R_EH1.00C ~_Lythem Ceramic Fibre Papers gr. 1535-LK [Gasket type |Gasket producer _ Lovac Supply Ltd, Kingston, Ontario __ [Cost miema. _ _Internat Appendix 2 Research Centre Page 1 of 2 Procedure for, and suppliers of, burner top flange gasket system in SS2/SS3, Porsgrumn 1. Procedure The gasket system consist of Loctite Permatex and a glass fibre packing. The procedure below must be carried out consecutively, as the Permatex will stiffen eventually, and become brittle ‘Tightening after this will break the Permatex, and the efficiency is lost. Apply Permatex to the bottom of the groove by means of brushing ("painting"). The purpose of this is to make the Permatex go into the glassfibre when the flange is tightened. Thickness of the Permatex layer is in the range | - 3 mm. Mount the glass fibre packing. Diameter of packing, and number of reels (coils) depends on the groove size. As an example, SS3 has a 40 mm wide and ca. 10 mm deep groove, and uses four reels of a 9.5 mm packing. Apply Permatex on top of glass fibre packing, sufficiently to cover well. SS3 needs a total of less than 11 (850 - 950 ml) for one burner. ‘Mount the flange and tighten. The tightening is carried out by means of a box spanner (socket spanner), and tightened until no futher movement can be felt. This can mean going around the bumer twice, as after the first round of tightening, the first bolt to be tightened is not tight any longer. The tightening continues until no difference can be noticed between to two bolts next to each other. Torque wrench is not used, as the plants do not have good experience of using it in this connection, Retightening is not required, not after shut-down either. Should a leak occur, then only the bolts in the vicinity of these leaks should be tightened. Removal of the gaskets cause no problem. When the flange has been properly tightened, the glass fibre packings can be removed by lifting the coils away. There will hardly be any left overs of either glass fibre or Permatex in the groove. When the tightening has been to strong, the gasket can resemble plaster and thus are more time consuming to remove. Dust masks should be used. 2. Suppli ‘Two components are being used: a braided glass fiber gasket (packing) and Loctite Permatex (to give complete sealing). The braided glass fiber packing. " (TBA) GP 1", is made specially by Flexitallic for the Norwegian gasket supplier C. Bagge A.S. It is a dry packing braided from continous filament "E" glass yarns (it is mainly used in smelting plants). The diameter used in SS2/SS3 is 9.5 mm (other diameters exist, from 3.0 to 25.0 mm). Hydro has a special agreement with C. Bagge AS, giving a substantial reduction in costs for the packings. MM:(vNy97R_EH1.DOCIntern: Appendix 2. Research Centre Page 2 of 2 ‘The addresses to C. Bagge AS and Flexitallic are given below: C. Bagge AS Flexitallic PO Box 146 PO Box 21 N-2020 Skedsmokorset Rochdale Phone: + 47 63 87 67 10 Lancashire OL12 TEU Fax: + 47 63 879797 Phone: +44 1706 71 5000 Fax: + 44 1706 46 055 Loctite Permatex "Form A Gasket" No.3_ is delivered by our well equipped local machinery store. This is a product based on resin and castor oil. The local store order it from the Norwegian Loctite representative, ‘The national Loctite representatives of applicable countries are given below: Norway: Loctite Norge AS Sandakerv. 102 1N-0483 Oslo Phone: +47 22 15 1490 Fax: 447 22 1537 55 Germany: Loctite Deucthland GmbH Arabellastrasse 17 D-81925 Miinchen Phone: +49 89 92.680 Fax: +49 89 910 19 78 England: Loctite UK Ltd. ‘Watchmead Welwyn Garden City Hertfordshire, ALT | JB Phone: +44 1707 821 000 Fax: +44 1707 821 200 Italy: Loctite Italia SPA Via Talete 56 1-20047 Brughertio Phone: +39 39 21 251 Fax: +39 39 88-46 72 MWv:(VNV97R_EH1.00C Sweden: Loctite Sweden AB Pb 8823 $-402 71 Goteborg Phone: + 46 31 50 54.00 Fax: + 4631 515154 ‘Netherland: Loctite Nederland BV Essendunk 5 NL-4824 Da Breda Phone: +31 76 542 23 33 Fax: +31 76 542 24 19 Loctite France SA 10 Avenue Eugene Gazeau BP 90 F-60304 Cenlies Cedex Phone: +33 344 2166 00 Fax: +33 344 2166 25, Canada: Loctite Canada IMC 270 Brittania Rd East Mississagua ONT.LAZ.186 Phone: +1 905 890 6511 Fax: +1 905 890 65114230 EXP. 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