GASKET SELECTION AND INSTALLATION

ENGINEER MUHAMMAD REHAN

engr.mrehan@yahoo.com

CONTENTSPre Test 1. What is a Gasket2. How Gasket Prevent leakage3. Gasket Specifications4. Sizes of Gasket5. Materials of Gasket6. Temperature-Pressure rating of Gasket 7. Types of Gasket8. Selection of Gasket 9. Piping Services at EPCL Plant10. Gaskets used at EPCL Plant11. Piping Specification at EPCL Plant12. Installation of Gasket13. Precautions for Gasket14. Loss due to Gasket Leakage 15. Gasket Leaks IncidentsPost TestQuestions can be asked anytime throughout the Training

PRE TEST

1. What is a Gasket Gaskets are used to create a static seal between two

stationary members of a mechanical assembly and to maintain that seal under operating conditions which may vary dependent upon changes in pressures and temperatures.

2. How Gasket Prevent Leakage?

Does Two flanges seal without gasket? If Yes then Why? If No then Why not?

3. Gasket Specification

SPECIFICATIONS EXAMPLE

Type of Gasket Full Face Gasket

Material EPDM

Size 3” (Vary from ½” to 24”)

Temperature- Pressure rating

150# (Vary from 150-2500 Class)

Standard B16.21 (Non-metallic Flat Gaskets for Pipe Flanges)

4. Sizes of Gasket ½ “ -24” As per application

5. Materials of Gasket

Will be discuss along with types

6. Temperature- Pressure Rating

ASME Pressure Classes: 150-2500 Class 150 means this Gasket can sustain

up to 150 psi maximum if the service temperature is around 550F.

Maximum working pressure increases with decrease in temperature

At 100F service temperature, the gasket can sustain 285 psi

7. Types of Gasket

7.1 Metallic 7.2 Semi Metallic7.3 Non metallic7.4 Liquid Gasket

or Sealant

7.1 Metallic Gasket

7.1.1 Solid Metal Ring7.1.2 Hollow Metal O-

Ring7.1.3 Corrugated

Metal

ASME B 16.20

7.1.1 Solid Metal Ring Shape: Octagonal and Oval Size: R, RX or BX number

Material: SS-304/316/321/347/410/F-5, Soft iron ‘D’, Hasteloy Inconel & Monel

Maximum P-T rating: 150-5000 Class Standard: ASME B16.20 Application: Flanges of ASME B 16.5,

ASME B 16.47, or API Specification 6A).

7.1.2 Hollow Metal O-Ring Material: Various grades of Inconel and

Stainless Steel Maximum Pressure: High Vacuum to

700MPa Maximum Temperature: Cryogenic to

1000C Application: Mechanical Seals

7.1.3 Corrugated Metal Material: Soft

aluminum, copper or brass, Metal Iron or soft steel, Inconel, Monel, SS304/ 316L

Maximum T-P rating: Class 150-2000

Application: Valves, Pumps, Heat Exchangers, Flanges, Vessels

7.2 Semi Metallic Gasket

7.2.1 Spiral Wound 7.2.2 Jacketed Metal Gasket

7.2.1 Spiral Wound Application: Flanges of ASME B16.5 &

B16.47 Standard: ASME B16.20

7.2.2 Jacketed Metal Gasket

Maximum P-T rating: Class 150-2500

Application: Heat exchangers, Boilers and flues, Autoclaves and other pressure vessels. Gas mains, Pumps, Valve bonnets and duties involving high temperature and dry heat.

7.3 Non Metallic

7.3.1 Rubber Gaskets 7.3.2 Graphite Sheet

Gasket 7.3.3 PTFE Sheet

Gasket 7.3.4 Compressed

Joint Sheet Gasket 7.3.5 Sealant Tapes

ASME B 16.21

7.3.1 Rubber Sheet Gasket Material:

i. Natural Rubber (-70F – 200F)ii. Styrene Butadiene Rubber (SBR) (-65F – 250F)iii. Chloroprene Rubber (Neoprene ®) (-60F – 250F)iv. Nitrile Butadiene Rubber (NBR) (-60F – 250F)v. Flouro carbon rubber (FKM) Viton ® (-15F – 450F)vi. CHLOROSULFONATED POLYETHELENE RUBBER (CSM) Hypalon®

(50F – 275F)vii. SILICONE RUBBER (VMQ) (-65F -500F)viii. ETHYLENE PROPYLENE DIENE RUBBER (EPDM) (-70F-350F)

Maximum Pressure: 150psi

7.3.2 Graphite Sheet Gasket

• Material: Graphite with/ without metal inserts

• Maximum Pressure: upto 250 Kg-F/cm2

• Maximum Temperature: -200-550C

7.3.3 PTFE Sheet Gasket

Material: PTFE Maximum Pressure: up to 124Kg-F/cm2 Maximum Temperature: -212- 316C Application: Virtually pH 0-14

7.3.4 Compressed Joint Sheet Gasket

Material: Asbestos, non-Asbestos and Fibre

Maximum Pressure: up to 100 Kg-F/cm2 Maximum Temperature: -100 - 300C

7.3.5 Sealant Tapes Material: PTFE, rubber, etc

7.4 Liquid Sealant Gasket

• Material: Silicon RTV• Maximum Temperature: -59C-329C

8. Selection of Gaskets

TAMP Temperature Application Material Pressure

9. Piping Services at EPCL Plant

Cooling Water, Waste Water, Boiler Feed Water, Raw Water, Demin & Polish Water

High and Low Pressure Steam, Condensate

Chlorine, HYPO, Hydrogen, Brine HCl, H2SO4, Caustic EDC, VCM , Vent Gases PVC Slurry Various Catalyst, reactants, agents, etc

10. Gasket used at EPCL Plant

Spiral Wound Ring Type Joint Non Asbestos PTFE Graphite Rubber Sheets Metal Jacketed RTV PTFE / Graphite Tapes

11. Piping Specification at EPCL

PVC 1 /UTY 1 = TOYO SPECS PVC 2/ CA/ UTY 2/ PP = CHINESE SPECS CA Electrolyzer = AKCC SPECS EDC/ VCM = FURMOSA SPECS

12. Installation of Gasket

Flange face cleaning Flange face inspection Flange alignment inspection

12. Installation of Gasket

Gasket Inspection Gasket Placement

12. Installation of Gasket

Bolts lubrication Bolts tightening

13. Precautions for Gasket

14. Gasket’s Failure Consequences

15. Gasket’s Failure Incidents

On 24th May 2004, A Hydrogen Fire took place due to the Installation of an Incorrectly Sized Gasket at a Solvent Manufacturing Plant

On 10th January 2000, approximately 100 barrels of jet fuel were discharged from Plantation Pipeline in Newington, Virginia, resulted from a failed gasket on an interface detector

On 22nd February 2003, approximately 788 barrels of gasoline were discharged from a portion of Plantation Pipeline in Hull, Georgia, resulted from a failed gasket on a buried block valve.

On 15th December 2004, Employees were performing maintenance on a propane pipeline near Mantador, North Dakota, when a gasket on the pipeline's valve failed, causing a leak. Nearby resident were evacuated, and a rail line was shut down temporarily. There were no injuries

QUESTIONS

Box up protocol at EPCL

Box up Certificate Signing of Flanges

POST TEST

Question 1

Can you use a 150# Class Flange with Steam service Pressure 250psi and Temperature 300F?

What would be the maximum Pressure that a 600# Class flange can bear at 800F?

Question 2

You have a purchase an Octagonal ring. What specifications you should send to the vendor if you know the following:

i. Material: SS 304ii. Avg. Pitch diameter of ring: 11.0“iii. Height of ring: 1.06”iv. Width of ring: 0.875”

Question 3

What would be the material of Metallic windings if Outer ring color is:

i. Brownii. Orangeiii. Greeniv. Bluev. Redvi. Yellow

HASTELLOY BMONEL 400

SS 316L

SS 347NICKEL 200

SS 304

Question 4

What would be the material of filler If the color of the marking on the outer edge of outer ring is

i. Whiteii. Grey

PTFE

FLEXIBLE GRAPHITE

Question 5

On what dimensions you will cut a rubber gasket for a Raised face Flange of 3” 150#

On what dimensions you will cut a PTFE Gasket for a Flat Face Flange of 2” 300#

Question 6

What are the two ASME Standards for Metallic and non-metallic Gaskets?

For Metallic: For Non-Metallic:

ASME B16.20

ASME B16.21

Question 7

Which one is not required in Gasket Selection?

i. Temperature of serviceii. Size of flangeiii. Pipe Internal Diameteriv. Service Compatibility

PIPE INTERNAL DIAMETER

Question 8

Which gasket should we use if the piping specification of a Chlorine Line is G1FF1?

Which gasket should we use if the piping specification of a Chlorine Line is A5S?

Question 9

Torquing of Bolts should be done in …… steps?

5

Question 10

Write down the steps involved in Gasket Installation?

i. Flange face cleaningii. Flange face inspectioniii. Flange alignment inspectioniv. Gasket Inspectionv. Gasket Installationvi. Bolts lubricationvii. Bolts tightening

THANK YOU