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By David Burgess
Piping is the circulatory system for manufacturing plants, delivering water, steam, compressed air, lubricants and other essential fluids where they’re needed. Piping has a direct effect on sustainability. Today’s piping systems pose challenges that can’t be met with conventional sealing methods.
Most industrial piping systems have numerous flanged joints, each one of which can fail, disrupting plant operations and incurring damage, downtime, lost production and, in some cases, injury and even death. Flanged joints typically fail as a result of insufficient gasket loading. Different types of gaskets seal best at different loads. For example, rubber gaskets seal at loads as low as 100 psi, whereas spiral-wound and metal-jacketed gaskets might require a minimum load of 5,000 psi to seal effectively.
Problems arise when service conditions indicate the use of one type of gasket, but the flange design suggests a different type. Fortunately, there are new gasket materials and configurations that can reconcile these conflicting criteria for more sustainable piping systems.
Industry made great strides in reducing the number of leaks from flanged joints, and some plants have even eliminated them. Because reliable piping system performance, including pumps, valves and other equipment, is critical to plant sustainability both operationally and environmentally, it’s vital to pay careful attention to these flanged joints and the gaskets that keep them from leaking.
Before replacing a leaking gasket, make sure you’ve identified the root cause of the leak. A good place to start is to verify that the proper gasket was installed in the first place based on the operating parameters of the system, notably temperature, media and pressure. The first consideration should be temperature because it can eliminate many unsuitable gasket materials from consideration. Next, look at the media’s chemical compatibility with the gasket, including any secondary media to which the gasket might be exposed, such as fluids that are intermittently present during chemical or steam/hot-water flushing. Then consider pressure. Most systems operate at relatively consistent pressure, but it’s important to take into account severe spikes or surges that might occur.
However, selecting the right gasket requires an understanding of the application that goes beyond these criteria. Flanged joints rarely leak because chemicals attacked the gasket. Most people understand that gasket materials must be compatible with system media. Likewise, it’s rare to find a piping system that exceeds a gasket’s maximum pressure or temperature ratings.
(Click to enlarge image) Figure 1. The causes of gasket leaks vary, but recent analysis of 100 randomly selected, failed gaskets indicated 68 correlated with insufficient load.
More often than not, flanged joint gasket failures derive from the mechanics of the application, resulting from incorrect compressive load. Eliminating such a simple cause requires knowing the type of flange in which the gasket will be installed, including the material and bolting information, to determine the compressive force. This is extremely important because nearly 70% of gasket failures are attributable to insufficient load (Figure 1).
This root cause might be uneven bolt loads, but it’s far more common that achieving proper loading was impossible given the flange design and available bolting. Under the same bolting scheme, a flat-faced flange with a full-face gasket, for example, won’t apply the same compressive force to the gasket as a raised-face flange with its smaller compressed area. Flange types that produce low compressive gasket loads include flat-faced cast iron flanges commonly found in valves and pumps; flanges on glass-lined equipment; nonmetallic flanges; rolled angle-iron flanges for ductwork; and flanges for vacuum service (Figure 2).
Figure 2. This compressed sheet gasket installed in a flat-faced flange failed because of insufficient compression
The available stress for these types of flanges varies widely. For example, an eight-inch, 150# raised-face flange and a ring gasket having a contact area of 32.2 square inches, a bolt stress of 60,000 psi and a bolt torque of 200 ft.-lbs. produces 4,800 psi of gasket compression. The same size flange with a flat face, fitted with an 80-square-inch, full-face gasket under the same bolt stress and torque, results in gasket stress of only 1,813 psi, about 38% of that from the ring gasket with its smaller contact area.
As a general rule, therefore, the best choice for raised-face flanges are ring gaskets made of compressed sheet, PTFE, graphite or metal. Use full-face rubber gaskets or gaskets with molded-in sealing rings with greatly reduced contact area for flat-face flanges.
Valves and pumps with flat flanges and standard ASME drilling can produce a stress between 1,000 psi and 2,000 psi; glass-lined flanges produce between 2,000 psi and 3,500 psi; flat-faced, non-metallic flanges from 150 psi to 500 psi; and angle-iron flanges around 100 psi to 300 psi. The bolting on some flanges used in vacuum service produces almost no compressive load.
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