Gasketing

BY : Manvir Guriyan

Contents 1) Basics of gasketing (i) What is gasket? (ii) Types of gasket, their properties and applications

2.) Common manufacturing processes and tolerances 3.) Assembly Method 4.) Design consideration , application & failure mode. (i) Selection of gasket material

What is Gasket
A gasket is a mechanical seal which fills the space between two or more mating surfaces, generally to prevent leakage from or into the joined objects while under compression.

Properties of Gasket
Ideal Gasket should have following properties: CompressibilityGaskets that have sufficient compressibility to suit the style and surface finish of the flange, ensuring that all the imperfections will be filled with the gasket material. ResilienceGaskets that have high resilience will enable the gasket to move with the dynamic loadings of the flange to maintain its seating stress. No change in thickness Gaskets that will not continue to deform under varying load cycles of temperature and pressure or under a constant load at elevated temperatures (creep).

Classification of Gaskets

Ring type gaskets

Full faced gaskets

According to material gaskets can be classified as: 1. Metallic & semi-metallic gaskets i) Corrugated Metal Gasket ii) Cam profile grooved gasket iii) Metal jacketed gaskets iv) Ring joints v) Spiral wound gaskets Non-metallic gaskets i) Fiber reinforced gasket ii) Graphite gasket iii) PTTE gasket iv) Rubber gasket

2.

Metallic & semi-metallic gaskets

i) Corrugated Metal Gasket
Applicable to high pressure (6.4~16.0Mpa) and high temperature (~650degree) location Strong corrosion resistance Stable and reliable sealing function. In case of metal to metal, a perfect flange surface (Ra < 32) is required

ii) Camprofile (grooved) gasket

Soft cover adapts flange surfaces with Ra<63 the trapped graphite provides good compressibility and resilience the cam profiled ring can be re-used again several times a good quality camprofile gasket can be very expensive

Soft cover

Outer ring Camprofile sealing ring

Metallic & semi-metallic gaskets

iii) Metal jacketed gaskets
Robust, can be handled and installed without special care Wide range of shapes Requires a good flange surface( Ra<16) because of metal to metal sealing Typical application for this type of gaskets are Heat exchangers, Boilers and flues, Autoclaves and other pressure vessels, Gas mains, Pumps, valve bonnets, Duties involving high temperature and dry heat Materials usually used Fillers - inert organic compounds, expanded graphite, Fluolion PTFE, ceramic fiber. Jackets - soft iron, low carbon steels, stainless steels, nickel alloys, aluminum, brass, copper, titanium.

Metallic & semi-metallic gaskets

iv) Spiral wound gaskets
covers a wide pressure and temperature range and is therefore a real multi purpose (universal) gasket the spiral wound gasket does not stick to the flange surface and can be easy removed has a good shelve life and requires no special care during handling and installation good resilience because of the V-shaped metal strips very popular gasket system and therefore good availability needs very parallel flange faces quality control difficult, as the quality of winding and the welding can not be checked Typical applications: High pressure industrial Pumps, Valves, Oil Steam, Gas pipelines joints, Heat Exchangers, Pressure Vessels, Manhole & Tube cap assembly in boilers, Nuclear reactors. Materials usually used: Standard fillers : expanded graphite, PTFE, ceramic, mica Standard metal : low carbon steel (paint or zinc plated finish), SS 316L, SS 304, SS 321, monel and other exotic materials are on demand

Outer ring

Inner ring
Intermediate film Metallic strip

Metallic & semi-metallic gaskets

v) Ring joints gaskets
Ring joints are designed to serve at high pressure (up to 1500 bar) and high temperature (up to 1000o C) applications. very safe and reliable sealing system; will be always applied, when aggressive media or explosive gases are involved risk in the choice of ring joint material: the ring joint material must be softer than the flange material but the hardness of the flange material is normally not indicated metal to metal sealing; requires therefore good (Ra < 16) flange surface Standard material used are soft iron, Low carbon steel, alloy steels F5 and 410, Stainless steels 304, 304L, 316, 316L 321, 347. The Ring Type Joint was initially developed for high pressure/temperature applications found in the petroleum industry and is primarily used in the oil field on drilling and completion equipment. However, today this product range can also be found on valves and pipe work assemblies, along with some high integrity pressure vessel joints

Non-metallic gaskets
i) Fiber reinforced gasket cheap and good availability easy to cut/punch to size limited in temperature resistance due to the rubber binder Commonly used fibers are aramide fiber, glass fiber, cellulose fiber, mineral fiber

glass fiber

aramide fiber

Non-metallic gaskets
ii) Graphite gasket can follow easy any flange irregularity, Ra < 125 no creeping no resistance in oxidizing environments

Non-metallic gaskets
iii) PTTE gasket very dense sealing material adapts perfect to the flange very good chemical resistance limited temperature resistance creeping

Non-metallic gaskets
iv) Rubber gasket adapts very good to the flange best resilience good sealing material very limited temperature resistance

Gasket material : It is usually desirable that the gasket be made from a material that is compressible such that it tightly fills the space it is designed for, including any slight irregularities. The most common misconception when selecting a gasket materials thickness is to choose a gasket material that is too thick. The thicker the material the more likely the material being contained can weep through the pores of the gasket material itself. This is a greater issue with some materials than others. A rule of thumb is to have the material thick enough to compensate for any surface face irregularities and to permit some compression. The required compression for your gasket material will depend many factors including: 1)Surface area 2)Pressure being sealed 3)Size of bolts (assuming bolts are being used) 4)Number of bolts 5)Condition of the bolts 6)Lubrication on the bolts

Factors Affecting Gasket Performance A gasket has one basic function: to create a positive seal between two relatively stationary parts. The gasket must do a number of different jobs well to function properly: first, create an initial seal; second, maintain the seal over a desired length of time; third, be easily removed and replaced. Varying degrees of success are dependent on how well the gasket does the following:

Seals system fluid. Chemically resists the system fluid to prevent serious impairment of its physical properties. Deforms enough to flow into the imperfections on the gasket seating surfaces to provide intimate contact between the gasket and the seating surfaces. Withstands system temperatures without serious impairments of its performance properties. Is resilient and resists creep enough to maintain an adequate portion of the applied load. Has sufficient strength to resist crushing under the applied load, and maintain its integrity when being handled and installed. Does not contaminate the system fluid. Does not promote corrosion of the gasket seating surfaces. Is easily and cleanly removable at the time of replacement.

Selecting the Right Gasket Selecting gasketing materials for particular applications is not an easy task. The variables present in a flanged connection seem endless and yet all of them must be taken into consideration to assure a proper seal. In the past, the acronym "TAMP" (Temperature, Application, Media and Pressure) seemed to give sufficient information to make a gasketing recommendation. Today, items such as: the flange metallurgy, the amount of bolt thread embedment, the amount of flange rotation, the amount of bolt stretch, the additives to the media and the flange surface finish (in addition to other variables) determine how well a gasket will perform. In general, the definition of what a seal is has changed drastically over the years. Leakage measurements have gone from drips a minute to parts per million. This information is designed to help guide you through the various gasketing products and narrow your choices. All industry standard tests are included in order to allow an enduser a means of comparison between different materials. Many of the test procedures require that the tests be conducted in 1/32" (0.8mm) material. As a rule of thumb, gasket performance decreases as material thickness increases. In addition, compressive loads must be increased with thicker materials. Proper bolting sequences are necessary to ensure those compressive loads are uniform. The temperature, pressure and P x T ratings are all based on optimum conditions. When approaching those extremes, it is suggested that you consult with the Garlock Applications Engineering Department or possibly upgrade to a material that has higher ratings.

As industry standards change and new products are introduced, this information will be updated. In the meantime, we urge you to take advantage of our experienced personnel for assistance. In-plant training, instructional video tapes, additional technical information and gasketing recommendations all are available to help in your selection process. Please feel free to call, FAX, e-mail or write us if you have any questions or concerns. Garlock is here to help. Temperature In most 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 200F (95C) to 1000F (540C). When system operating temperatures are approaching 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 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. We have calculated and tabulated this information on standard ANSI raised face flanges. Compressive stress on non-standard flanges must be calculated on an individual basis and is available upon request. Without this information, we can not choose between various types of materials such as elastomeric (rubber) gaskets, compressed sheet, GRAPh-LOCK and GYLON styles. Media There are thousands of different fluids. We cannot make recommendations for all fluids. Fortunately, however, a relatively limited number of fluids make up the vast majority of the media encountered in industry. A general overview of fluid compatibility is provided for our most popular styles. System clean out and flushes should also be considered. Additional information on products versus fluids is available upon request. Pressure Next to be considered is the internal pressure of the fluid at the gasketed joint. We list the maximum pressure limits for each style. If severe and frequent pressure changes are involved, we should be given the details, since an alternative product may be needed.

Pressure: psi (bar) x Temperature: F (C) Values We strongly recommend that pressure and temperature be considered simultaneously by using the following procedure: Select the Garlock style(s) being considered for your application/service List the maximum pressure, temperature and P x T value for the style(s), Make sure the actual service conditions do not exceed the style limitations in any of the three criteria. If the service conditions don't exceed the style limitations, the style(s) can be used, assuming all other requirements are met. If they do exceed any one limit, another style or styles should be considered. Rarely can a style be recommended when the service conditions of pressure and temperature are both at the maximum limits for that style. Example: BLUE-GARD Compressed Asbestos-Free Gasketing Style 3000: Pressure Limit: 1,000 psig (70 bar) Maximum Temperature Limit: +700F (+370C); Continuous Operating Temp.: +400F (+205C) P x T Limit: 350,000* (12,000) At 1,000 psig (70 bar), maximum temperature is +350F (+180C). Important: All pressure and P x T limits are based on laboratory tests utilizing ideal gasketing conditions. Field conditions will undoubtedly affect the gasket performance. We hasten to point out that this method for gasket selection is merely a general guide and should not be the sole means for selecting or rejecting a product. *P x T based on 1/16" (1.6mm) sheet thickness unless otherwise stated. GRAPH-LOCK, GYLON and BLUE-GARD are registered trademarks of Garlock Inc.

Gasket Design Tips

Material Selection The first seal or gasket design consideration is to determine whether an application calls for sponge or dense material. Along with this initial determination, closing force requirements need to be considered. The primary difference between sponge and dense from the design standpoint, by example: If the application requires a very low closing force, such as a door seal on a consumer-type product, then a sponge cross-section is most likely best suited, or; If the application requires a great deal of interference between the two surfaces, such as the bolting together of two components in an industrial setting. Then a dense section is the preferred choice. In either instance, material selection depends upon the physical characteristics and attributes needed in the application. A second consideration in the material selection process is the sealing environment. Will there be heat or cold present? Are there solvents or other chemicals present? Is it static or dynamic sealing application? Will the material be required to stand up against UV and ozone exposure? Once these questions are answered, it becomes easier to match the right material to the application. A third consideration is exactly how the seal or gasket will be attached. Is a particular part to be attached by compression fit into a channel? Will an adhesive be applied to the seal? Or, will there be some sort of mechanical attachment, i.e.; staples, nails, or clips? (For an explanation of pressure sensitive adhesive attachment systems, refer to this section in the guide on Pressure Sensitive Adhesives.)

Design Criteria Cross-Sectional Design Several things need to be known about the application before you can properly determine what good cross-sectional design will be. Knowing the attachment system is important how the seal will be attached to the substrate or to the application. What is the gap or the opening the seal is going to fit into and be expected to seal? This includes both the minimum and maximum amounts of gap that exists throughout the application, taking into account tolerances of the enclosure and sealing material. In most cases, the general effective compression range is 2% to 10%. It is important to remember that the end use always needs to be considered. For example, there is a very significant difference between sealing a box to keep out dust, and sealing that same box to keep out moisture when it is submerged in ten feet of water. What is the amount of closing force that will be tolerated in the application? A seal requiring 50 pounds of force to seal is not going to work in an application where only 20 pounds of force will be tolerated. How much force is required on the seal, how much surface area, the type of material that is used, and the size of the cross section all need to be considered. The direction in which the load is applied to the seal is also a critical factor. Very different results will occur if a 60o load is applied as opposed to a 90o load. There are also ways to help reduce or control the total amount of load required to get a good seal: (1) The shape of the cross-section can be changed, depending on how the load is applied; and (2) holes or hollow sections can be introduced into the crosssection to help reduce the load required to compress the seal. For example, a dense D section will have a higher mechanical load than one that has been hollowed" out.

Compression Application Design When designing compression fit applications, it is necessary to have the same 15% to 25% compression in the channel for sponge sections to hold the seal in place. By the same token, for dense sections, the 2% to 10% compression listed above is necessary to hold the seal in the channel. As before, this is somewhat dependent upon the application, such as the size of the channel itself and the direction from which the load is applied. Adhesive Attachment Application Design The attachment surface would be wider that 1/8 to ensure proper attachment. For dynamic situations, the minimum strip of adhesive to hold the seal in place until the mating substrates are joined. In addition, the adhesive placement should be on flat surfaces on both the seal and the substrate. Transfer adhesives generally perform better than supported adhesives (adhesives that use a carrier) when it comes to bending around radii. On the other hand, supported adhesives help prevent stretching of the seal during application better than transfer adhesives. The thickness of the PSA itself should be taken into consideration when determining the overall height of the profile. Mechanical Seal Attachment Application Design When designing seals that will be attached mechanically, accommodation must be made for the insertion of the attachment device (clip, nail, staple) to the seal. The seal design has to be such that the mechanical attachment device does not interfere with the compression of the seal.