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Practical Maintenance Blog Archive Gaskets - Testing, Selection and Installation-Gasket
Practical Maintenance Blog Archive Gaskets - Testing, Selection and Installation-Gasket
on
Mechanical Maintenance
Compiled by: K P Shah
Test Procedures
Gasket Standards
Gasket Selection
Installation Procedure
Storage of Gaskets
Test Procedures
Gaskets are tested to find out their physical properties. Various important ASME and DIN test procedures for
testing of gaskets are as under.
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Gasket Standards
Various standards are used to specify gasket dimensions and properties as under.
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Gasket Selection
Primarily gasket selection is based upon temperature of media, pressure of media, compatibility of gasket
material for the media and application. It is suggested that gasket shall be selected for above parameters in
following sequence.
Temperature
In selection processes, the temperature of the fluid at the gasketed joint should be considered first. This will
reduce the number of product candidates quickly, especially as temperatures go from 200°F (95°C) to 1000°F
(540°C). Gasket shall withstand system temperature without serious impairment of its performance properties.
When system operating temperatures approach a particular gasket material’s maximum continuous operating
temperature limit, an upgrade to a superior material is suggested. In some situations cryogenic temperatures must
also be considered.
Application
The most important information under application is the type of flange (flat face, raised face, tongue and groove,
ring joint flange, etc.), flange metallurgy (steel, nonmetallic, glass lined, etc.) and bolts used. The number, size
and grade of bolts used in the application determines the load available. The surface area being compressed is
calculated from the gasket contact dimensions. The load from the bolts and the contact area of the gasket result in
the compressive load available to seal the gasket. Selection of gasket shall also take care of minor misalignment,
flange bowing (flange bending), and flange surface imperfections like – waviness, grooves, scoring and finish.
Gasket shall have sufficient strength to resist crushing under the applied load, and maintain its integrity when
being handled and installed.
Media
Gasket material shall chemically resist the system fluid to prevent serious impairment of its physical properties.
Pressure
Gasket shall be strong enough to resist internal fluid pressure.
Notes:
Maximum temperature and pressure capabilities do not necessarily operate to gather for all gasket thicknesses
and it is recommended that pressure and temperature are considered simultaneously using P x T Limit of a gasket
for different gasket thicknesses.
For gaskets cut from sheets, always use the thinnest material which the flange arrangement will allow, but thick
enough to compensate for unevenness of the flange surfaces, their parallelism, surface finish and rigidity etc. The
thinner the gasket, the higher the bolt load which the gasket can withstand, and the less the loss of bolt stress due
to relaxation. Also the gasket area will be lower which will be exposed to attack from the internal pressure and
aggressive media. In view of this, ensure that the gasket is as thin as possible. As a rule of thumb, gasket
performance decreases as material thickness increases.
Caution:
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their selection.
Important:
Always use a good quality gasket from a reputable supplier, because the cost of a gasket is insignificant when
compared to the cost of downtime or safety considerations.
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Flanges
There are limits on the degree of flange surface imperfection that can be sealed successfully with a gasket. Large
nicks, dents, or gouges must be avoided, since a gasket cannot properly seal against them. The surface finish of a
flange is described as roughness, lay and waviness.
Roughness is read in millionths of an inch as the average of the peaks and valleys measured from a midline of the
flange surface. This is expressed either as rms (root mean square) or AA (arithmetic average). The difference
between these two methods of reading is so small that they may be used interchangeably.
Lay is the direction of the predominant surface roughness pattern. Example: multidirectional, phonographic
spiral serrations, etc.
Waviness is measured in thousandths or fractions of an inch. Basically, it is the departure from overall flatness.
Generally most manufacturers provide recommendations about appropriate flange surface finishes for particular
gasket materials. Recommended values of roughness are as under.
Spiral Wound Gaskets: 125-250 rms
Jacketed or Metal Clad Gaskets: 63-80 rms
Solid Metal Gaskets: 63-80 rms
It is recommend that a flange be machined using a 1/16" radius, round nosed tool to have 30-55 serrations per
inch in a concentric or spiral pattern.
The lay of the finish should follow the midline of the gasket if possible. Take, for example, concentric circles on
a round flange. Every effort should be made to avoid lines across the face, such as linear surface grinding
allowing a direct leak path.
Waviness is seldom a problem under normal conditions. There are two areas that must be watched since
excessive waviness is very difficult to handle. The first area is glass-lined equipment where the natural flow of
the fused glass creates extreme waviness. Often the answer here is to use thick and highly compressible gasket.
The second area of concern is warped flanges. If warpage is caused by heat or internal stresses, remachining is
generally sufficient. However, warpage due to excessive bolt loads or insufficient flange thickness results in what
is generally called bowing. The solution is to redesign for greater flange rigidity. Sometimes backer plates can be
added to strengthen the design without having to replace the parts. Another solution would be to add more bolts.
Bolting
For the majority of flange and gasket joints, the fasteners which provide the compressive pressure on the flanges
(and through this onto the gasket) are normally bolts or studs in tension.
Fasteners exhibit stress relaxation behaviour dependent upon their material of construction. This will have a
marked effect on the load they are able to generate on the flange / gasket assembly under operating conditions.
Consequently, when selecting the fasteners to use for a particular application, always consider the temperature
variations which the fasteners will experience in service. Recommended values are as under.
Recommended fastener working temperatures
Temperature °C (°F)
Material
Minimum Maximum
Carbon steel -20 (-4) 300 (572)
B7, L7 -100 (-148) 400 (752)
B6 0 (32) 500 (932)
B8 -250 (-418) 575 (1067)
B16 0 (32) 520 (968)
B17B -250 (-418) 650 (1202)
B80A -250 (-418) 750 (1382)
Tension loads above the elastic limit will produce some permanent deformation. The fastener will not return to its
original length and its effectiveness as a spring clamp will be impaired. In view of this, select fasteners with
sufficient yield strength to ensure they are within their elastic limit at the required load.
The tension in the fastener is generated by tightening nuts along the threads of the fastener. The threads therefore
play a major role in the clamping operation, and care must be exercised to maintain their integrity. Threads will
strip when the axial forces on the fastener exceed the shear strength of the threads.
Threads strip more readily when fastener and nut material are of the equal strength. For optimum safety, use a nut
which has a specified proof load 20% greater than the ultimate strength of the fastener. In this way, the fastener
will break before the nut threads will strip. A break is easier to detect than a stripped thread.
Flat, hardened washers should always be used with fasteners to reduce significantly the friction between a
turning nut and the joint components. This improves the consistency of the torquing operation improving
accuracy and reducing the torque required. Use the same material for the washers and that of nuts.
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Installation Procedure
The most common cause of leaky gasketed joints is improper installation procedures. Care shall be taken at all
stages given below.
Handling of Gaskets
When working in the field, carry cut gaskets carefully. If you bend the gasket it will be damaged. Always
transport large diameter metallic and semi-metallic gaskets to the installation site on its mounting / packing.
Visual Inspection
Inspect various components as under.
Fasteners / nuts / washers – after cleaning examine them to assure freedom from defects such as burrs or cracks.
Flange assembly – inspect the flange surfaces for defects, such as radial scores and warping. Ensure that the
flange surfaces are sufficiently flat and parallel.
Gasket – check that the correct gasket is available (suitable for the service, size,
thickness). Examine the gasket prior to installation to ensure that it is free from defects.
If any defect is observed, replace defective components with a good alternative.
Lubrication
It is estimated that in the absence of a suitable lubricant, up to 50% of the torque effort may be used to merely
overcome friction. Effectively, this would mean that the same torque applied to non-lubricated fasteners on a
joint might provide markedly different loads on each one. Therefore, lubrication is essential when torque is used
as the control for setting tension in the joint. After cleaning, lubricate fastener threads and all bearing surfaces
(underside of bolt heads, nuts, washers) with a quality lubricant such as an oil and graphite mixture. Ensure that
lubricant does not contaminate either flange or gasket faces.
Gasket Installation
Carefully insert the new gasket between the flanges to prevent damage to the gasket surfaces and center it. Do
not use tape to secure the gasket to the flange. If it is necessary to secure the gasket to the flange, use a light
dusting of spray adhesive (e.g. 3M type 77). Do not use jointing compounds or release agents on gasket / flange
faces.
Pass 1 – Tighten nuts loosely by hand in the first instance, according to the cross bolt tightening pattern, then
hand-tighten evenly.
Pass 2 – Using a torque wrench, torque to a maximum of 30% of the full torque first time around, according to
the cross bolt tightening pattern.
Pass 3 – Torque to a maximum of 60% of the full torque, according to the cross bolt tightening pattern.
Pass 4 – Torque to the full torque, according to the cross bolt tightening pattern.
Pass 5 – Final pass at full torque, in a clockwise direction on adjacent fasteners.
After the five basic torquing passes are completed, it may be beneficial to repeat pass 5 until no further rotation
of the nut is observed. The final tightening must be uniform, with each bolt pulling the same load.
Hydraulic tensioners are often used to preload fasteners. In this method when the tensioner load is applied, the
nut is run down against the joint (finger tight). The hydraulic pressure is then released and the tensioner removed.
Another way to tighten large bolts is to insert a heating rod in a hole drilled down through the centre of the bolt.
As it heats up, the bolt expands length wise, and the nut can be run down against the joint (finger tight). The
heater is now removed, and as the bolt cools, it shrinks, so developing tension.
Re-tightening
For the majority of materials in the flange system (including gaskets, fasteners, nuts, washers), relaxation sets in
after a fairly short time. For soft gasket materials, one of the major factors is usually the creep relaxation of the
gasket. These effects are accentuated at elevated temperatures. Due to this the compressive load on the gasket is
reduced, increasing the possibility of a leak. Consequently, some engineers recommend that fasteners should be
re-tightened (to the rated torque) 24 hours after the initial assembly. Re-tightening shall always be carried out at
ambient temperature. However, this is an area of conflicting views!
Elastomer-based CAF gasket materials continue to cure in service, especially on start up as the operating
temperature is reached. Once fully cured, gasket materials may become embrittled and liable to cracking under
excessive load, and this is especially the case with elastomer-based asbestos-free materials. As it is impossible to
predict the time for embrittlement, always consult the manufacturer for advice about re-tightening. As a general
rule do not re-torque an elastomer-based asbestos-free gasket after it has been exposed to elevated temperatures.
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Storage of Gaskets
Although many gasket materials can be used safely after storage for many years, ageing will have a distinct
effect on the performance of certain types of gasket materials. Primarily, this is a concern with materials which
are bonded with elastomers. They in general should not be used after about 5 years from the date of manufacture.
If required, they shall be used only after careful inspection. Materials with elastomeric binders will inevitably
deteriorate over time, and even more quickly at higher ambient temperatures. Degradation is also catalysed by
intense sunlight. Since graphite and PTFE materials contain no binders, sheets and gaskets of these materials
have a virtually indefinite shelf life. In general,
During storage gaskets should not be subjected to extreme heat or humidity – store in a cool, dry place,
away from direct sunlight, water, oil and chemicals.
Store sheet materials flat.
Avoid hanging gaskets – they may distort. Store soft gaskets flat. Large diameter spiral wound gaskets
should be retained on their mounting board.
Gaskets should be kept clean and free from mechanical damage (for maximum protection, store in sealed
poly bags).
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Flange insulation sets comprise the following components which ensure that full electrical isolation is achieved.
Central insulating gasket which is fitted between the flanges.
Insulating sleeve per flange bolt.
Insulating washers per flange bolt.
Metal backup washers per flange bolt.
The components are manufactured from insulating materials with high compressive strength and good stability
DTI's stay on the job, providing permanent visual and measurable proof that the bolt is correctly tensioned to
specification. Gap corresponds to bolt load verified by a test certificate traceable to NIST.
Reuse of a Gasket
A gasket’s function is to conform to flange high and low spots when compressed, and its ability to reseal
decreases after it is compressed. Gaskets which contain rubber and which have experienced elevated
temperatures will be even less likely to reseal. In view of this, it is recommended not to reuse a gasket. Even if
the gasket appears to be okay, it is not worthwhile. The cost of a new gasket is minuscule compared to the cost of
down time caused by a leak or blowout and the considerations of safety and environmental protection.
Spacers in Flanges
Some installations require a very thick gasket to fill a large gap between flanges. It is recommended not to stack
numerous gaskets in the same flange. Tests have shown that a better way to fill a 1/2" gap, for example, is to
install a 1/16" gasket on each side of a 3/8" thick incompressible spacer ring. Ideally, the spacer ring shall be
consistent with piping metallurgy, serrated, and cut to the same dimensions as the gasket. Higher minimum
torque is recommended when using this type of arrangement.
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