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GASKETS
1 Introduction ………………………………………………………….. 6
2 Types of Gaskets......................................................................... 8
2.3 O-rings............................................................................... 11
3 Flange Gaskets............................................................................ 16
4 Gasket Fitting............................................................................... 27
4.1 Preparation........................................................................ 27
5 Making a Gasket.......................................................................... 33
6 Summary...................................................................................... 35
7 Glossary....................................................................................... 36
Appendix A................................................................................... 37
Appendix B................................................................................... 40
Exercises 1- 5............................................................................... 43
Work hardening A process that makes some metals harder when they are
hammered or bent.
In the last module of this course (Pipework) you learnt about flanges and the
need for gaskets in flange joints. In this module you will learn more about the
different types of gaskets that are available and their applications.
Gaskets are a type of static seal. They form leak-proof joints between
surfaces that do not move relative to each other. Figure 1.1 shows examples of
typical gaskets.
Static means not
moving or stationary.
prevent fluid from leaking out from between the surfaces of a joint
They are used between pipe flanges, the halves of split casings, on inspection
covers in containers, etc.
It is very difficult, and expensive, to machine metal surfaces so that they are
flat and smooth enough to provide a leak-proof joint. Gaskets are made of
relatively soft materials. When a gasket material is squashed in a joint, it fills
the spaces caused by the roughness of the surfaces being sealed.
For some very low-temperature applications on the plant, gaskets are not
used. The flanges must then have a very good surface finish: they must be
very smooth, and that makes them very expensive.
The choice of gasket for a joint depends on the fluid being contained, its
pressure and temperature and the surrounding atmosphere. It is, therefore,
very important to use the correct gasket for every application.
The type of gasket used for any application and the material it is made of
depends on four things:
operating pressure
operating temperature
The simplest gaskets are made of sheet material. The material used depends
on the four things listed above and on the surface finish of the surfaces
being sealed. The thinnest sheet gaskets can be made of paper. If the
contained fluid damages ordinary paper, it can be treated with varnish or
greaseproof paper is used. Handle paper gaskets carefully as they break
easily. Figure 2.1 shows some typical paper gaskets.
Rubber—a very flexible material that comes in Synthetic materials are man-
made, usually from petroleum
different densities and sheet thickness. Synthetic products in a petrochemical
plant.
rubbers (elastomers) are not affected by oils and
many chemicals.
Examples of gaskets made from these materials are shown in Figure 2.2.
A composite gasket is made up of (or composed of) more than one material.
These materials are in different layers. This type of gasket is usually ready-
made. Some examples of composite gaskets are shown in Figure 2.3.
Rubber o-rings are circular-section (‘O’-section) rings. They are located in a groove
in one of the surfaces being sealed. Figure 2.4 shows a rubber o-ring and its
section when cut through.
O-rings usually form static seals between two surfaces. Figure 2.5 shows
an o-ring located in its groove in a small water pump casing.
O-ring
Cover
O-ring
groove
O-ring
Casing
Engine
crankcase
Distributor
clamp bolt Distributor
Spigot body
O-ring
solid metal
metal jacketed
Solid metal gaskets are made of a soft metal like copper or aluminium.
Like all gaskets, they should normally only be used once. Squashing a
metal gasket work hardens it. You can re-use some solid metal ring-gaskets
by heat treating them before replacing them. This heat treatment is called
annealing. It is a process that softens a work hardened metal. This is only
done where you can not get a new replacement gasket. Figure 2.8 shows
solid metal ring-gaskets.
Metal o-rings are hollow to allow them to be more easily crushed. You cannot
re-use them. Figure 2.9 shows a metal o-ring before and after use. It also
shows a drawing of the o-ring section before and in operation.
Before use
In operation
Metal-jacketed gaskets are often used where complicated shapes are needed.
A wide range of temperature and pressure is possible as there is a large
range of materials and styles that can be used. The soft filler material can be
completely or partially enclosed in the metal jacket. Heat exchanger
gaskets are often of the type shown in Figure 2.10(a) above.
Corrugated gaskets have a wavy surface that can help form a good seal.
This is shown in Figure 2.10(b) above.
Another form of sealant is a flexible expanded PTFE strip. The strip is usually
self- adhesive and is applied as shown in Figure 2.11(b).
®
(a) Loctite Liquid Sealant (b) PTFE Sealant
What has been said so far about gaskets is also true for flange gaskets.
Because flange gaskets perform such an important job on plants, we will
look at them in more detail in this section.
ring gaskets
full-face gaskets
Ring gaskets fit inside the circle of flange studs and so do not have holes for
the studs. Full-face gaskets cover the whole flange face so they need stud
holes. Simple examples of these two types of gaskets are shown in Figure
3.1.
Full-face flange gaskets are described by the five dimensions shown in Figure 3.2.
OD
PCD
ID
OD Outside Diameter
Stud
ID Inside Diameter Diameter
Material
thickness
Full-face gaskets are used with flat-face (FF) flanges. Flange types are
described in the Pipework module. A flat-face flange with a full-face gasket is
shown in Figure 3.3.
Gasket
Ring gaskets fit inside the circle of studs. They have no stud holes and their
dimensions are described by their OD, ID and thickness only. Do not fit ring
gaskets to cast iron or bronze flanges. These materials are brittle and
tightening down causes uneven loading that can crack the flange.
You can fit ring gaskets to flat-face or raised-face flanges as shown in Figure 3.4.
(a) Ring Gasket on Flat-face Flanges (b) Ring Gasket on Raised-face Flanges
If the fluid pressure being contained is very high, the gasket can blowout
across the flange face. This happens as the fluid in the pipe tries to
escape between the flange faces, see Figure 3.5(a).
Ring gaskets that fit into a groove in the flange can take higher pressures.
The groove stops the gasket from being pushed outwards (radially), see
Figure 3.5(b).
Fluid
Fluid pressure
pressure
(a) FF Flanges with no Groove to Stop Blowout (b) Groove-to-flat Flanges Reduce Blowout Risk
The gasket shown in Figure 3.6(d) on the last page is a special type of ring
gasket. It is called a spiral-wound gasket. A spiral is the name of a shape that
can by coiled up on a flat surface, as shown in Figure 3.7(a). It is often
confused with a helix, shown in Figure 3.7(b).
All spiral-wound gaskets have a v-section metal strip wound in a spiral. There
is a filler material between each coil of the spiral that helps to seal the joint.
Some spiral- wound gaskets have an outer ring, some an inner ring and
some have both rings. A section through a typical spiral-wound gasket with
inner and outer rings is shown in Figure 3.8.
Outer ring
Inner ring
An outer ring makes it easier to align the gasket centrally inside the studs.
The ring gives the gasket more radial strength, reducing the risk of blowout. It
can also protect the spiral winding from the outside atmosphere, which might
be corrosive. A gasket with an outer ring is usually fitted to raised-face
flanges, as shown in Figure 3.10.
Gasket section
spiral
outer ring
Gasket section
spiral
inner ring
Gaskets with both rings have the advantages of both the last two types.
They are usually fitted to raised-face flanges as shown in Figure 3.12.
Gasket section
spiral
outer ring inner ring
Spiral wound gaskets are identified by their size, rating and materials.
Identification information is shown on the face of the gasket as shown in Figure 3.13.
non-metal filler
outer ring
inner ring
The correct material for each of these parts of the gasket depends on its application.
As shown in Figure 3.13, the materials of the outer and inner rings are
marked as codes on those parts of the gasket; in this example the code is
304 for both. If the
The material for the winding and filler is also shown as a code, marked on
the outer ring; in this example it is 304/FG. If the gaskets are made to the
American Society of Mechanical Engineers (ASME) Standard B16.20, winding
and filler materials are also color coded. These color codes and the number
codes for stainless steels are shown in Figure 3.14.
Figure 3.14: ASME B16.20 Color Codes for Spiral-wound Gasket Metallic Windings and Non-
metallic Fillers
The band of color on the outer edge of the gasket tells you what the filler
material is. Look at Figures 3.13 and 3.14 and you will see that:
the code marked on the outer ring is 304—the outer ring is 304 stainless steel
the code marked on the inner ring is 304—the inner ring is 304 stainless steel
the color of the outer ring is yellow—the winding is also 304 stainless steel
the color band on the outer edge is grey—the filler is flexible graphite (FG)
Note that the code marked on the outer ring surface for the winding and
filler also shows 304/FG: 304 stainless steel and flexible graphite.
Insulating kits fitted to bolts and flanges stop the flow of electric current. A
typical insulating kit is shown in Figure 3.15.
Electric current passes easily through metals. They are good electrical
conductors (i.e. poor insulators). Current can pass from one metal flange to
the other directly across the flange faces and through the metal fixing studs.
The insulation kit makes sure that no metallic item on one side of the flanges
touches the other side.
A gasket made out of a poor conductor of electricity (i.e. a good insulator) fits
between the flanges. This insulates one face from the other.
Insulating sleeves fit inside the stud holes. These stop studs from touching
the sides of the holes. Insulating washers between the back of the flange and
the steel washers stop nuts and washers from touching the flanges. The kit
shown in Figure 3.15 has one-piece insulating washers and sleeves.
Gaskets are designed to seal between mating faces. These faces should have
a surface finish that is suitable for the application and the gasket specified.
4.1 Preparation
After removing a gasket, you must make sure that the faces to be sealed are
completely clean before re-fitting. Remove any pieces of old gasket
A trace is a very
carefully. If a sealant has been used, clean all traces of the small quantity of
something.
sealant from the faces. You may need to use a scraper to do
this but make
sure that you do not scratch or damage the surface. Any material remaining
on the faces or any damage to them reduces the surface finish. This affects
the ability of the gasket to seal the joint.
Do not re-use an old gasket when you re-assemble a gasketed joint. Even if
it does not look damaged, a gasket is compressed during service. It may
have been under high pressure and temperature. Once it has been used, its
properties will have changed. It will not meet the required specification and
could fail in service.
Make sure the gasket is aligned accurately with the edges of the face and
any bolt holes. Paper and other thin gaskets can be difficult to keep in place
during assembly.
A thin smear of light grease or Vaseline® on one face can hold the
gasket in place.
A smear is a
thin coating.
4.2 Bolt Load
it pushes outwards between the joint faces, trying to blowout the gasket
Figure 4.1 shows the forces that act on the gasket and the bolts because
of fluid pressure inside a container.
Tensile force on
bolts due to fluid
pressure
Fluid
pressure
Blowout force on
gasket due to
fluid pressure
Fluid
pressure
If you tighten the fixing bolts too much, the fluid pressure acting on them can
damage them. Materials like steel have a property called elasticity. They can
be extended by a force and then return to their original length when the
force is removed, like a spring. But, there is a limit to how much you can
extend them without damaging them. If you extend a material too much, it
will not return to its original length, it becomes permanently stretched or
deformed. If you keep adding more force, the material breaks (or fails)
The point at which the material becomes permanently deformed is called the
elastic limit.
If nuts are tightened too much, the bolt material goes past its elastic limit. The
bolts become permanently deformed. If you continue to tighten them, or if
something like fluid pressure adds more tensile force, they will break. This is
why you should not tighten nuts to more than the recommended torque.
When the temperature of the fixing bolts increases, they get bigger. We say
that they expand. When they expand, their length increases. This reduces
the clamping force on the gasket. Tightening torques must be enough to
allow for this expansion in service.
Joints that contain high pressure and/or high temperature fluid in service
must be tightened to the manufacturer’s recommended torque values.
start
start
1 7 1 4
6 4
end
6 5
3 5
2nd dia.
8 2 3rd dia. 3 2
end
8 4 1 5 9
12 13
11 14
7 3 2 6 10
For the rectangular layout in Figure 4.2(c), one correct way is to start from the
central nuts and work outwards in a spiral, as shown.
Make sure that all threads are clean, then lubricate them with oil or grease.
Dry and dirty threads can cause the torque wrench to give a false reading.
Some torque is used to overcome friction if a thread is difficult to turn. Then,
only part of the set torque is used to tighten the nuts.
Finger-tighten all nuts first. Then use the torque wrench, following any
recommendations from the equipment manufacturer or standing instructions.
start
1 2
end
8 3
7 4
6 5
7. tighten gradually—make more than one pass until you reach the final torque
8. make a final pass at the recommended torque, going around the nuts in turn
You can make your own gaskets out of sheet material. Of course, you can
only use these where simple, sheet material gaskets are specified. Always
be aware that the gasket type and material is important for many
applications on the plants. Always replace a gasket with one of the same
specification.
You can measure and mark out a gasket, as you would any work piece.
You may be able to mark out the shape by covering the metal sealing face
with something that transfers to the gasket material, like grease or engineers
blue. Then, pressing the metal face onto the gasket material marks it with
the shape of the face and shows any hole positions.
With these methods you need to cut out the gasket shape with snips or a
sharp blade.
Figure 5.1 shows these two cutting methods.
®
(a) Cutting with Snips (b) Cutting with a Stanley Knife
Punch
Gasket
material
Blank
Ring gasket
Another way to make simple gaskets is to use a ball pein hammer as shown in
Figure 5.3(a) and (b).
Gently hammering around the metal edge cuts through the gasket material.
In this module you have seen examples of the many different gaskets.
You have learnt the importance of selecting the correct gasket for the job.
You have also learnt more about tightening sequences and the importance of
using the correct torque values when tightening gasketed joints.
Here are some words used in this module that might be new to you. You will
find these words in coloured italics in the notes. There is a short definition in
a box near the word in the notes.
First Part of
Word Meaning Example of Use
Used on Speech
Page:
Irregularities 27 noun Sudden There were so many
changes— not irregularities on the
continuing in a track that we were
steady, being shaken to pieces
recognizable in our car.
pattern or
Occasional 12 adjective Not often normal
following Although I live in Abu
rules. Dhabi I have only
made the occasional
visit to Al Ain.
2" - 12" 150# RF BS 1414, MATL. CS BS 1504-161 GR 480, 13% CR. TRIM NOTE 8
1½" & 800 # FS SW PISTON TYPE BS 5352, MATL. BS 1503-221-430, 13% CR.
CHECK BELOW TRIM
NOTE 12
VALVES 150# RF SWING TYPE BS 1868, MATL. CS BS 1504-161 GR 480, 13% CR.
2" - 24"
TRIM
2" SCH. 40
FLANGES 300# WN RF BS 1560, MATL. ASTM 105 OR BS 1503-221-430
(ORIFICE) 8" - 16" SCH. 30
SW FITTINGS 1½" & BELOW SCH. NIPPLES API 5L, GR. B OR ASTM A 106
160 GR. B
SCH. 80 SWAGE NIPPLES BS 3799, GR. WPA/WPB
SCRD.
FITTINGS
SOCKOLETS 1½" & BELOW -- 3000# MATL. ASTM A 105
1&
T BRANCH REINFORCEMENT
SMLR
1½ S T T = TEE
2 S S T UB = UNREINFORCED BRANCH
3 S S W T S = SOCKOLET
4 S S W W T W = WELDOLET
HEADER 6 S S W W W T NOTE: FOR BRANCH DETAILS
SIZES (IN
REFER TO BECHTEL STD
INCHES) 8 S S W W W UB T
DRG: AL-865
10 S S W W W UB UB T
12 S S W W W UB UB UB T
14 S S W W W UB UB UB UB
16 S S W W W UB UB UB UB
18 S S W W W UB UB UB UB
1&
1½ 2 3 4 6 8 10 12
SMLR
BRANCH SIZES (INCHES)
8"
B. W. BS 1640, PART 4, MATL. GR. 321/ASTM A 403 GR. WP-S 321
10" - 16"
FITTINGS NOTE 1
18"
20" - 24"
1½" & BELOW SCH. 80
SOCKOLETS 1½" & BELOW -- 3000# MATL. ASTM A 182 GR. F321
1&
SML T BRANCH REINFORCEMENT
R
1½ S T T = TEE
2 S S T UB = UNREINFORCED BRANCH
3 S S W T S = SOCKOLET
4 S S W W T W = WELDOLET
HEADER
SIZES (IN 6 S S W W W T
INCHES) 8 S S W W W T
10 S S W W W T
12 S S W W W T
14 S S W W W T
16 S S W W W T
18 S S W W W T
1&
SMLR 1½ 2 3 4 6 8 10 12 14 16 18
BRANCH SIZES (INCHES)