RELIANCE GROUP Module No.

Gaskets
TRAINING MODULE RG-CM-G - 001

GASKET

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 1 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

CONFIDENTIALITY STATEMENT

This Training manual is prepared exclusively for the technical knowledge

enhancement of the personnel of Reliance Group of Industries.

No part of this document may be reproduced in any form, in an electronic

retrieval system or otherwise. The document must be returned or when the
recipient has no further use of the same. The document or any part of the
document is not allowed to be taken out of the respective site or to be
shared with any person outside Reliance Group.

Reliance Group of Industries reserves the right to refuse access to the

above document on the grounds of confidentiality.

Authorization for information disclosure is allowed with the written

permission of the respective Site Engineering Head.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 2 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

TRAINING MODULE OBJECTIVE

This Training manual is intended to help engineers to understand the basic

fundamentals of a Gasket. It is often said that a gasket is leaking but this is
not strictly correct because truly it is the joint which leaks and Gasket is
only one component of the several that makes one joint. Hence it has been
experienced that for the gaskets, it takes more time to identify the problem
than to solve it. Thus, in this module, an effort has been made to provide
much needed source of information in the field of Gaskets.

To make the module easy to use, contents are divided into short sections
like Gasket introduction, Selection criteria, Installation guide, Trouble
shooting, Types of Gaskets, Do’
s & Don’
ts etc.

It is hoped that users may suggest improvements in future editions, to

make this module more useful.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 3 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

TABLE OF CONTENTS
Sr. No. Description Page No
1.0 Introduction 06
1.1 Why Gaskets Are Use 06
1.2 How Gasket Seal 07
1.2.1 Gasket Seating Stress “Y” 09
1.2.2 Gasket Factor “M” 09
2.0 Type of Gaskets 13
2.1 Based on Shape 13
2.2 Based on Material of Construction 15
2.2.1 Soft Sheet Gaskets 15
2.2.2 Semi Metallic Gasket 17
2.2.3 Metallic Gaskets 21
2.3 Spiral Wound Gaskets 23
3.0 Gasket Materials 27
3.1 Soft Gasket Materials 28
3.2 Metallic Gasket Materials 33
4.0 Application of Types of Gaskets 38
5.0 Gasket Selection 40
5.1 Flange Design 40
5.2 Surface Finish 40
5.3 Selection of Gasket Materials for different services 43
6.0 Installation 45
6.1 Installation and Maintenance Tips 45
6.2 Gasket Installation Procedures 45
Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 4 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

7.0 Trouble Shooting Guide 50

8.0 Trouble shooting Leaking Joints 54
9.0 Sealing layer Material and Sealing Stresses 56
9.1 Core Thickness 57
9.2 Gasket Consist of a Metal Core 58
10 Do’
s & Don’
ts 59
11 Standards 61
11.1 Material Standards 61
11.2 Dimension Standards 61

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 5 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

1.0 Introduction

A gasket is some softer material usually inserted between contact faces to obtain
fluid tight joints. Tightening the bolts causes the gasket material to flow into the
minor machining imperfections resulting in a fluid-tight seal.

1.1 Why gaskets are used

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 temperature. If it were
possible to have perfectly mated flanges and were possible to maintain an
intimate contact of these perfectly mated flanges throughout the extremes of
operating conditions a gasket would not be required. This is virtually impossibility
either because of:

• The size of the vessel and /or flanges

• The difficulty in maintaining such extremely smooth flange finishes during

handling and assembly

• Corrosion and erosion of the flange surfaces during operations

As a consequence, relatively inexpensive gaskets are used to provide the sealing

element in these mechanical assemblies. In most cases, the gasket provides a
seal by external forces flowing the gasket material into the imperfections
between the mating surfaces. It follows then that in a properly designed gasket
closure, Three major considerations must be taken into account in order for a
satisfactory seal to be achieved.
Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 6 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Sufficient force must be available to initially seat the gasket. Stating this another
way, adequate means must be provided to flow the gasket into imperfections in
the gasket seating surfaces

Sufficient force must be available to maintain a residual stress on the gasket

under operating conditions to ensure that the gasket will be in intimate contact
with the gasket seating surfaces to prevent blow-by or leakage.

The selection of the gasket material must be such that it will withstand the
pressure exerted against the gasket, satisfactorily resist the entire temperature
range to which the closure will be exposed and withstand corrosive attack of the
confined medium.

1.2 How gaskets seal

When closed, a gasket seal is subject to a compressive stress produced by

assembly. Under working conditions this load may be relieved by hydrostatic end
thrust as shown in below fig no1. The gasket is subject to a side load due to
internal pressure tending to extrude it through the flange clearance space. To
resist extrusion the compressive load should be greater than the internal
pressure and remain so. A factor of atleast 2 is usually recommended to allow for
relaxation of gasket compression stress, which is normally inevitable. This in turn
will depend on the material. A material with a low relaxation is preferable as it
can be employed with lower initial compression pressure, or maintain factor of
safety at the same pressure.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 7 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Gasket creates a static seal between two members of an assembly and maintains
the seal during operating condition that may fluctuate. Seal is provided by the
gasket flowing in to imperfections in the mating surfaces. Force to affect the seal
is provided by bolting compressing the gasket.

TYPICAL JOINT DIAGRAM

Hp Total joint-contact-surface compression load in lbs

Hydrostatic end force in lbs
H
∆F Change in joint load due to the gasket relaxing in lbs
Fbo Initial required tightening force in lbs
Total tightening force required to seal joint in lb
W
FIG NO 1A

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 8 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

1.2.1 Gasket Seating Stress “Y”

Sufficient force is necessary to deform the gasket in to the imperfections. The

“Y” is defined, as the applied stress required to seat the gasket up on the
flanges. For gasket design, the necessary compressive stress is the function of
flanges surface finish, gasket material, density, thickness, fluid to be sealed and
allowable leak rate.

1.2.2 Gasket Factor “M”

Sufficient force must be present during operation to maintain the seal against the
internal pressure to prevent leakage. For gasket design, the required ratio of

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 9 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

gasket compressive stress to internal pressure depends upon the gasket style
and materials. The “M” is defined, as the residual compressive force exerted
against the gasket contact area must be greater then internal pressure when the
compressive force has been relieved by the hydrostatic end force. It is the ratio
of residual gasket contact pressure to internal pressure and must be greater then
unity otherwise leakage would occur. It follows then; the use of higher value for
“M”would result in a closure design with a greater factor of safety.

“Y” and “M” have no theoretical values but are empirical, developed form
experience. Gasket material must be suitable for the temperatures, pressures
and environment to which it is exposed. Filler material is generally Graphite or
some times Teflon or another Non – Asbestos material.

“M”and “Y”values are given below for different types of gaskets

Gasket material Gasket Min.

factor design
“M” seating
stress “Y”
in N/mm2

Rubber without fabric or a high percentage of asbestos ξ

fiber:

*below 75°BS and IRH 0.5 0 0

75°BS and IRH or higher 1.0 0 1.4

Asbestos ξ with a suitable 3.2 mm thick 2.0 11.0

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 10 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

binder for the operating 1.6 mm thick 2.7 5 25.5

conditions 0.8 mm thick 3.5 0 44.8

Rubber with cotton fabric insertion 1.2 5 2.8

Rubber with asbestos ξ fabric insertion, 3 – ply 2.25 15.2

with or without wire reinforcement 2 – ply 2.50 20.0

1 - ply 2.75 25.5

Vegetable fiber 1.7 5 7.6

Spiral-wound metal, Carbon 2.5 0 To suit

asbestos ξ filled Stainless or monel 3.0 0 applicant

Corrugated metal, asbestos ξ Soft aluminium 2.50 20.0

inserted or Corrugated metal, Soft copper or brass 2.75 25.5
Jacketed asbestos ξ filled Iron or soft steel 3.00 31.0

Monel or 4 to 6% chrome 3.25 37.9

Stainless steels 3.50 44.8

Soft aluminium 2.75 25.5

Soft copper or brass 3.00 31.0

Corrugated metal Iron or soft steel 3.25 37.9

Monel or 4 to 6% Chrome 3.50 44.8

Stainless steels 3.75 52.4

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 11 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Flat metal jacketed Soft aluminium 3.25 37.9

Asbestos ξ filled Soft copper or brass 3.50 44.8

Iron or soft steel 3.75 52.4

Monel 3.50 55.1

4 to 6% Chrome 3.75 62.0

Stainless steels 3.75 62.0

Soft aluminium 3.25 37.9

Soft copper or brass 3.50 44.8

Grooved metal Iron or soft steel 3.75 52.4

Monel or 4 to 6% Chrome 3.75 62.0

Stainless steels 4.25 69.5

Soft aluminium 4.00 60.6

Soft copper or brass 4.75 89.5

Solid flat metal Iron or soft steel 5.50 124

Monel or 4 to 6% Chrome 6.00 150

Stainless steels 6.50 179

Ring joint Iron or soft steel 5.50 124

(for dimensions see BS 1560) Monel or 4 to 6% Chrome 6.00 150

Stainless steels 6.50 179

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 12 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Rubber O- rings :

below 75°BS 0 to 0.25 0.7

between 75°and 85 °BS and IRH 1.4

Rubber square section rings :

below 75°BS and IRH 0 to 0.25 1.0

between 75°and 85 °BS and IRH 2.8

Rubber O- rings :

below 75°and IRH 0 to 0.25 1.0

between 75°and 85 °BS and IRH 2.8

ξ New non-asbestos bonded fiber sheet gaskets are not necessarily direct
substitutes for asbestos-based materials. In particular pressure, temperature and
load limitations may be applied.

2.0 TYPE OF GASKETS

Gaskets can be classified based on shapes or based on Material of construction.

2.1 Based on shapes

Although shapes and dimensions very enormously there are certain shapes
common to most industries. Chiefs among these are flange gaskets produced to various
standards. The two most common types of gaskets are:

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 13 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

FIG NO 2

FIG NO 3

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 14 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

2.1.1 Inside bolt circle or ring type

Where the periphery of the gasket is generally located by the bolts.

2.1.2 Full Faces type

Where the out side diameter is similar to that of the flange and has a series of
holes corresponding to the number and diameter of the bolts.

These types are illustrated in Fig no 2 & 3.

2.2 Based on Material of Construction

Based on this criteria the gaskets can be classified in to three types

1) Nonmetallic or Soft sheet gaskets

2) Semi-metallic

3) Metallic

2.2.1 Soft Sheet Gaskets :

They are also called non-metallic gaskets. Usually composite sheet materials are
used with flat face flanges and low pressure class application. Non metallic
gaskets are manufactured with nonasbestos material or Compressed Asbestos
Fiber (CAF). Non-asbestos types include arimid fiber, glass fiber, Natural Rubber,
elastomer, Teflon (PTFE), and Flexible Graphite. These types of gaskets can be
classifies in to following categories
Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 15 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

A) Fiber gaskets

• Major advantages:

Ü Low cost

Ü Comfortable surfaces

• Major disadvantages :

Ü Possibility of blowout

Ü Rubber binder /composite

Ü Structure makes chemical compatibility complex

B) PTFE Based gaskets

• Major advantages:

Ü Highly chemically resistant

Ü Extremely soft surfaces

Ü Approved in “clean”operations such as food processing

• Major disadvantages:

Ü Low temp. limit

Ü Creep relaxation notorious

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 16 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Ü Blowout failure possible

Ü High cost

C) Graphite based gaskets

• Major advantages:

Ü Highly chemically resistant

Ü Extremely soft surfaces

Ü High temperature limit

Ü Approved in some clean operations such as nuclear industry

• Major disadvantages:

Ü Poor handleability

Ü Possibility of blowout

Ü Oxidation

2.2.2 Semi-metallic:

Semi metallic gaskets are composites of metal and nonmetallic material. The
metal is intended to offer strength and resiliency, while the nonmetallic portion
of a gasket provides conformability and sealability. Commonly used semimetallic
gaskets are Spiral wound, Metal jacketed, Camprofile and variety of metal

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 17 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

reinforced graphite gaskets. Semimetallic gaskets are designed for wide range of
operating conditions of temperature and pressure. They can be classified as:

A) Spiral Wound Gasket :

The spiral wound gaskets are used most commonly in Hydrocarbon industries.
They have been described separately below.

B) Jacketed :

Jacketed gaskets are made from non-metallic gasket material enveloped in a

metallic sheet. This inexpensive gasket arrangement is used occasionally on
standard flange assemblies, valves and pumps. Jacketed gaskets are easily
fabricated in a variety of sizes and shapes and are an inexpensive gasket for
heat exchangers, shell, and channel and cover flange joints. Their metal seal
makes them unforgiving to irregular flange finish and cyclic operating conditions.

The main features are as follows:

• Made of a metallic outer shell with either a metallic or non-metallic filler

• Very durable, easy to handle

• Less expensive

• Requires a smooth flange finish (100 rms., max)

• Poor memory (not good for cycling)

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 18 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Fig No 4

Fig No 5

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 19 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Jacketed heat exchanger gasket

• Made of a metallic outer shell with either a metallic or non-metallic filler

• Very durable, easy to handle

• Less expensive

• Requires a smooth flange finish (100 rms., max)

• Poor memory (not good for cycling)

C) Camprofile :

Camprofile gaskets are made from a solid serrated metal core faced on each side
with a soft nonmetallic material.

The term Camprofile (or Kammprofile) comes from the groove profile found on
each face of the metal core. Two profiles are commonly used: the DIN 2697
profile and the shallow profile. The shallow profile is similar to DIN profile except
that the groove depth is 0.5 mm (versus 0.75mm for DIN). The most common
facing for Camprofile gaskets is graphite. Other facings such as expanded or
sintered PTFE and CAF are also used. The Camprofile gasket combines the
strength, blowout and creep resistance of a metal core with a soft sealing
material that conforms to the flange faces providing a seal.

Camprofile gaskets are used on all pressure classes from class 150 to class 2500
in vide variety of service fluids and operating temperatures.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 20 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Fig No 6

2.2.3 Metallic:

Metallic gaskets are fabricated from one or a combination of metals to the

desired shape and size. Common metallic gaskets are Ring Joint gaskets and
Lens ring. They are suitable for high temperature and pressure applications and
require high bolt load to seal.

A) Ring joints:

Standard Ring joint gaskets can be categorized in to three groups: Style R, RX

and BX.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 21 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

FIG NO 7
Style R gaskets are either oval or octagonal. The style RX is pressure
energized adaptation of the standard style R. The BX pressure
energized are designed for use on pressure systems up to 20,000 psi.

The main features are as follows:

• Initially developed for use in petroleum industry, high

pressure/temperature

• No recovery , not good for cycling

• Requires very smooth finish, 63 rms. Max.

• Manufactured in accordance with API 6A 7 ASME B16.20

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 22 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

• Blow out resistant

B) Lens rings:

Lens ring gaskets have a spherical surface and are suited for use with conical
flanges. They are used in specialized high temperature and pressure applications.

Other specialty metallic seals are available, including welded membrane gaskets
and weld ring gaskets. These gaskets come in pairs and are seal welded to their
mating flanges and to each other to provide a zero leakage high integrity seal.

2.3 Spiral wound gaskets

Spiral Wound gaskets are the most common gaskets used, hence they have been
described here specially. They are used in all pressure classes from Class 150 to
Class 2500. The part of the gasket that creates the seal between the flanges
faces is the spiral wound section. It is manufactured by winding a performed
metal strip and a soft filler material around a metal mandrel. The inside and
outside diameters are reinforced by several additional metal windings with no
filler. Please refer Fig no 8 for construction details of Spiral wound gaskets

The features of Spiral Wound gaskets are as follows:

• Well established

• Wide range and combination of materials

• Variable density

• Well suited to cyclical

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 23 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

• Blow out resistant

• Cryogenics to extremely high temperatures (1100 °c)

• Vacuum to high pressure(175kg/cm 2)

• Ease of flange clean-up

2.3.1 Sizing Spiral wound Gaskets

Fig No 8

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 24 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Spiral wound gaskets must be sized to ensure the spiral wound component is
seated between flange surfaces. If it protrudes beyond a raised face or into a
flange bore mechanical damage and leakage may occur.

2.3.2 Variable density

Spiral wound gaskets are manufactures by alternately winding strips of metal

and soft fillers on the outer edge of winding mandrels that determine the inside
dimensions of the wound component. In the winding process, the alternating
plies are maintained under pressure. Varying the pressure during the winding
operation and / or the thickness of the soft filler, the density of the gasket can
be controlled over a wide range. As a general rule, low winding pressure and
thick soft fillers are used low-pressure applications. Thin fillers and high-pressure
loads are used for high-pressure applications. This of course would account for
the higher bolt loads that have to be applied to the gasket in high-pressure
applications. In addition to all these advantages of the spiral wound gasket, they
are relatively low cost. When special sizes are required, tooling costs are very
nominal.

Gasket confined on I.D. and O.D.

Gasket I.D. = Groove I.D. + 1/16”

Gasket O.D = Groove O.D.+ 1/16”

Gasket confined on O.D. only

Gasket I.D. = Bore + Minimum ¼”

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 25 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Gasket O.D.= Recess O.D. –1/16”

Gasket unconfined I.D. and O.D.

Gasket I.D. = Seating surface I.D. + Minimum ¼”

Gasket O.D = Seating surface O.D. - Minimum ¼”

Centering guide = Bolt circle Diameter – Dia of the Bolt

Gasket Unconfined I.D. and O.D.

Gasket Dia I.D. O.D.

Up to 1” +3/64” –0 +0 –1/32”

1”to 24” +1/32” – 0 +0 – 1/32”

24”to 36” +3/64” – 0 +0 – 1/16”

36”to 60” +1/16”– 0 +0 – 1/16”

60”and above +3/32” – 0 +0 – 3/32”

2.3.3 Inner and outer Rings

For application involving raised face flanges, the spiral wound gasket is supplied
with an outer ring, for critical applications it is supplied with both outer and inner
rings. The outer ring provides the centering capability of the gasket as well as
the blow out resistance of the windings and acts as compression stop. The inner
ring provides additional load bearing capability from high bolt loading. This is

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 26 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

particularly advantageous in high-pressure applications. The inner ring also acts

as barrier to the internal fluids and provides resistance against buckling of the
windings.

Reasons to use them

1. Contains and protects sealing elements

2. Prevents buckling (when properly sized)

3. Required by ASME B 16.20 for PTFE, and recommended where buckling is

a problem

4. Recommended for vacuum service

5. Directs more of the bolt load to the sealing element

6. Prevent erosion of the flange face

Loose or integral rings:

Thermal-shock conditions may damage with integral centering rings (thermal

tension may cause cracks in the core).

3.0 Gasket Materials

Gasket materials can be divided in two-category i. e. Soft or Non metal and other
one is Metal. They are described in detailed below.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 27 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

3.1 Soft gasket Materials

A “soft gasket”material is a term used when referring to a gasket material that is

easily compressed under a low bolt load. This term has been used to distinguish
the difference from a metallic gasket. A soft gasket material can be selected from
a large variety of rubbers (neoprene, viton, SBR, EPDM, etc), TFE, graphite, and
compressed non- – asbestos sheet products. Soft gaskets are used in a wide
range of applications from pipe flange, heat exchanger, compressor and bonnet
valve gaskets to name just a few. Soft gasketing material can be purchased in a
variety of cut shapes or be provided in sheet or rolls.

3.1.1 Natural Rubber

Natural rubber has good resistance to mild acids and alkalis, salt and chlorine
solutions. It has poor resistance to oils and is not recommended for use with
ozone. Its temperature range is very limited and is suitable only for use from –
56°c to 93°c.

3.1.2 SBR (Styrene- Butadiene)

SBR is a synthetic rubber that has good resistance and has good resistance to
weak organic acids, alcohol’
s, moderate chemicals and ketones, It is not good in
ozone, strong acids, fats, oils, greases and most hydrocarbons. Its temperature
limitations are approximately –51°c to 120°c.

3.1.3 CR (Chloroprene)

Chloroprene is a synthetic rubber that is suitable for use against moderate acids,
alkalis and salt solutions. It has good resistance to commercial oils and fuels. It is
Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 28 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

very poor against strong oxidizing acids, aromatic and chlorinated hydrocarbons,
Its temperature range would be from approximately –51 °c 120°c.

3.1.4 Buna-N Rubber (Nitrile, NBR)

Buna-N is a synthetic rubber that has good resistance to oils and solvents,
aromatic and aliphatic hydrocarbons, petroleum oils and gasoline’
s over a wide
range of temperature. It also has good resistance to caustic and salts but only
fair acid resistance. It is poor in strong oxidising agents, chlorinated
hydrocarbons, ketones and esters. It is suitable over a temperature range of
approximately –51°c 120°c.

3.1.5 Fluorocarbon (Viton)

Fluorocarbon elastomer has good resistance to oils, fuel, chlorinated solvents,

aliphatic and aromatic hydrocarbons and strong acids. It is not suitable for use
against amines, esters, ketones or steam. Its normal temperature range would
be between -26°c to 232°c.

3.1.6 Hypalon (Chlorosulfonated Polyethylene)

This material has good acid, alkali and salt resistance. It resists weathering
sunlight and ozone, oils and commercial fuels such as diesel and kerosene. It is
not good in aromatics or chlorinated hydrocarbons and has poor resistance
against chromic acid and nitric acid; its normal temperature range would be
between -45°c to 135°c.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 29 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

3.1.7 Silicones

Silicon rubbers have good resistance to hot air, they are unaffected by sunlight
and ozone. They are not, however, suitable for use against steam, aliphatic and
aromatic hydrocarbons. The temperature range would be between -53 °c to
260°c.

3.1.8 EPDM (Ethylene Propylene-Diene Monomer)

This synthetic material has good resistance to strong acids, alkalis, salts and
chlorine solutions. It is not suitable for use in oils, solvents or aromatics
hydrocarbons. Its temperature range would be between -56 °c to 176°c.

3.1.9 Grafoil

This is an all graphite material containing no resins or inorganic fillers. It is

available with or without a metal insertion, and in adhesive-back tape form for
pipe gaskets over 24 inches in diameter. Grafoil has outstanding resistance to
corrosion against a wide variety of acids, alkalis and sail solutions, organic
compounds, and heat transfer fluids, even at high temperatures. Its use against
strong oxidizing agents at elevated temperatures should be investigated very
carefully. In addition to being used as a gasket, grafoil makes an excellent
packing material and is also used as a filler material in spiral-wound gaskets.

3.1.10 Ceramic Fiber

Ceramic fiber is available in sheet or blanket form and makes an excellent gasket
material for hot air duct work with low pressures and light flanges. It is

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 30 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

satisfactory for service up to approximately 1093 °c. Ceramic material is also used
as a filler material in spiral-wound gaskets.

3.1.11 Plastics

Of all plastics, PTFE (polytetrafluoroethylene) has emerged as the most common

plastic gasket material. PTFE’
s out standing properties include resistance to
temperature extremes from -95 °c to 232°c (for virgin material). PTFE is highly
resistant to chemicals, solvents, caustics and acids except free fluorine and alkali
metals. It has a very low surface energy and does not adhere to the flanges.
PTFE gaskets can be supplied in a variety of filler material such a glass, carbon,
molybdenum disulfide, etc. The principal advantage in adding fillers to PTFE is to
inhibit cold flow or creep relaxation.

3.1.12 Compressed non-asbestos sheeting

Early efforts to replace asbestos resulted in the introduction and testing of

compressed non-asbestos products in the 1970’
s. Many of these products have
seen extensive use since that period however there have been enough problems
to warrant careful consideration in choosing a replacement material for
compressed asbestos. Most manufactures of non-asbestos sheet materials use
synthetic fibers.

3.1.13 Vegetable fiber sheet

Vegetable fiber sheet is a tough pliable gasket material manufacturer by paper

making techniques utilizing plant fibers and a glue-glycerin impregnation; it is
widely used for sealing petroleum products, gases and wide variety of solvents.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 31 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Its maximum temperature limit is 120°c. If a more compressible material is

required, a combination cork-fiber sheet is available. The cork-fiber sheet has the
same max temperature limitation as the vegetable fiber sheet.

3.1.14 CMG

Corrugated Metal Graphite (CMG) is a high performance gasket for standard

flange or heat exchanger applications. This gasket offers:

• High sealability

• Conformity where low bolt load is available

• Maintain high bolt loads, upon re-tightening, in heat exchanger

applications.

• Heavy gauge corrugated insert for support

• Choice of insert metals

The CMG molds in place by filling in irregularities of the spaces creating a

superior seal. It maintains the seal even in harsh environment including
hydrocarbons and steam applications. You can specify CMG for applications
where there is:

• Low bolt loads or high available gasket stresses

• Restricted area for flange separation making it impossible for a spiral

wound type

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 32 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

• A need to substitute compressed asbestos or non-asbestos gasket for a

variety of applications

3.1.15 CM-PTFE

Corrugated metal faced on both sides with expanded PTFE

(polytetrafluroethylene). The standard construction of a “CM-PTFE” features a
corrugated 316ss metal core. The design of this type gasket allows for a wide
variety of metals to select from to meet special process criteria. The PTFE
selection for the face material gives you the chemical resistance for aggressive
applications.

CM-PTFE Benefits:

• High creep resistance

• Chemical resistance

• Conforms to the irregularities in flange faces for a tight seal with low
minimum sealing stress

• Superior memory characteristics ensure that bolts remain tight so that re

torquing is not necessary

3.2 Metallic gasket Materials

3.2.1CARBON STEEL

Commercial quality sheet steel with an upper temperature limit of approximately

1000°F., particularly if conditions are oxidizing Not suitable for handling crude
Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 33 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

acids or aqueous solutions of salts in the neutral or acid range. A high rate of
failure may be expected in hot water service if the material is highly stressed.
Concentrated acids and most alkalis have little or no action on iron and steel
gaskets, which are used regularly for such services. Brinell hardness is
approximately 120.

3.2.2 STAINLESS STEEL 304

An 18-8 (Chromium 18-20%, Nickel 8-10%) Stainless with a maximum

recommended working temperature of 1400 °F. At least 80% of applications for
non – corrosive services can use type 304 stainless in the temperature range of –
320°F to 1000°F. Excellent corrosion resistance to a wide variety of chemicals.
Subject to stress corrosion cracking and intergranular corrosion at temperature
between 8000F to 15000F. In presence of certain media for prolonged periods of
time. Brinell hardness is approximately 160.

3.2.3 Stainless Steel 304L

Carbon content maintained at a maximum of 0.03% recommended maximum

working temperature of 1400 °F. Same as excellent corrosion resistance as type
304. This low carbon content tends to reduce the precipitation of carbides along
grain boundaries. Less subjected to intergranular corrosion than type 304. Brinell
hardness is about 140.

3.2.4 Stainless Steel 316

An 18-12 Chromium – nickel steel with approximately 2% of molybdenum added

to the straight 18-8 alloy. Which increases its strength at elevated temperatures

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 34 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

and results in somewhat improved corrosion resistance. Has the highest creep
strength at elevated temperatures of any conventional stainless type. Not
suitable for extended service within the carbide precipitation range of 800 ° to
1650°F. When corrosive conditions are severe. Recommended maximum working
temperature of 1400 °F. Brinell hardness is approximately 160.

3.2.5 Stainless Steel 316L

Continuous maximum temperature range of 1400 °- 1500°F. Carbon content held

at a maximum of 0.03%. Subject to a lesser degree of stress corrosion cracking
and also intergranular corrosion than type 304. Brinell hardness is about 140.

3.2.6 Stainless Steel 321

An 18-10 chromium- nickel steel with a titanium addition. Type 321 stainless has
the same characteristics as type 347. The recommended working temperature is
1400°to 1500°F and in some instances 1600 °F. Brinell hardness is about 150.

3.2.7 ALLOY 20

45% Iron, 24% Nickel, 20% Chromium and small amount of molybdenum and
copper. Maximum temperature range of 1400 °- 1500°F. Developed specifically
for applications requiring resistance to corrosion by sulfuric acid. Brinell hardness
is about 160.

3.2.8 ALLOY 1100

Alloy 1100 is commercially pure (99% minimum). Its excellent corrosion

resistance and workability makes it ideal for double-jacketed gaskets. The brinell

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 35 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

hardness is approximately 35. For solid gaskets, strong alloys like 5052 and 3003
are used. Maximum continuous service temperature of 800 °F.

3.2.9 BRASS

Yellow brass 268 has 66% copper and 34% Zinc. Offers excellent to good
corrosion resistance in most environments, but is not suitable for such materials
as acetic acid, acetylene, ammonia, and salt. Maximum recommended
temperature limit of 500°F. Brinell hardness is 58.

3.2.10 COPPER

Nearly pure copper with trace amounts of silver added to increase its working
temperature. Recommended maximum continuous working temperature of
500°F. Brinell hardness is about 80.

3.2.11CUPRO NICKEL

Contains 69% Copper, 30% Nickel, and small amounts of manganese and iron.
Designed to handle high stresses, it finds its greatest application in areas where
high temperature s and pressures combined with high velocity and destructive
turbulence would rapidly deteriorate many less resistant alloys. Maximum
recommended temperature limit of 500 °F. Brinell hardness is about 70.

3.2.12HASTE ALLOY 276

16-18% Molybdenum, 13-17.5% Chromium, 3.7-5.3% Tungsten, 4.5-7% Iron,

and balance is nickel. Maximum temperature range of 2000 °F. Very good in
handling corrosives. High resistance to cold nitric acid of varying concentrations

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 36 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

as well as boiling nitric acid up to 70% concentration. Good resistance to

hydrochloric acid. Excellent resistance to stress corrosion cracking. Brinell
hardness is about 210.

3.2.13 INCONEL 600

Recommended working temperature of 2000 °F and is some instance 2150 °F. Is a

nickel based alloy containing 77% Nickel, 15% Chromium and 7% Iron. Excellent
high temperature strength. Frequently used to overcome the problem of stress
corrosion. Has excellent mechanical properties at the cryogenic temperature
range Brinell hardness ids about 150.

3.2.14 INCOLOY 800

32.5% Nickel, 46% Iron, 21% Chromium. Resistant to elevated temperatures,

oxidation, and carbonization. Recommended maximum temperature of 1600 °F.
Brine hardness is about 150.

3.2.15 MONEL

Maximum temperature range of 1500 °F. Contains 67% Nickel and 30% Copper.
Excellent resistance to most acids and alkalis, except strong oxidizing acids.
Subject to stress corrosion cracking when exposed to fluorosilic acid, mercuric
chloride and mercury, and should not be used with these media. With PTFE it is
widely used for hydrofluoric acid service. Brinell hardness is about 120.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 37 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

3.2.16 TITANIUM

Max temperature range of 2000 °F. Excellent corrosion resistance even at higher
temperatures. Known as the “ Best solution” to chloride iron attack. Resistance
to nitric acid in a wide range of temperatures and concentrations. Most alkaline
solutions have little if any affect upon it. Outstanding in oxidizing environments.
Brinell hardness is about 215.

Note: -

Maximum temperature ratings are based upon hot air constant temperatures.
The presence of contaminating fluids and cyclic conditions may drastically affect
the maximum temperature range.

4.0 Application of types of gaskets

Pressure class

Gasket type Low class Medium High class Max temp of

class materials ( °C)
150-300 1500-2500
600-900

Non Metallic

CAF X - - 343 – 538

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 38 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Non asbestos X - - 288

fiber

PTFE X - - 199 – 288

Graphite X - - 399

Semi Metallic

Metal jacketed X X - 399+ *

Metal reinforced X X - 399+ *

graphite

Spiral wound X X X 399+ *

Camprofile X X X 399+ *

Metallic

Ring joint - X X 343+ *

gaskets

Lens ring - X X 343+ *

Machined ring - X X 343+ *

X - Applicable

- - Not applicable

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 39 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

* - Depends on material

5.0 Gasket selection

The proper selection of gasket is critical to the success of achieving long- term
leaks tightness of flanged joints. Due to their wide spread usage, gaskets are
often taken for granted. Industry demands for reduced flange leakage in
environments of increasing process temperatures and pressures have led gasket
manufacturers to develop a wide variety of gasket types and materials, with new
gaskets being introduced on an ongoing basis. This rapidly changing
environment makes, and will continue to make, gasket selection difficult.

5.1 Flange design

Flange design details, service environment, and operating performance guide the
gasket selection process. Start with the flange design. Identify the appropriate
flange standard, outlining size, type, facing, pressure rating, and materials (i.e
ASME B16.5, NPS 4, Class 1500, RF, and carbon steel). Identify the service
environment of temperature, pressure, and process fluid. It is useful to highlight
gasket –operating performance.

5.2 Surface finish

Surface finish is important as it governs the thickness and compressibility

necessary in the gasket material to complete a physical barrier in the clearance
gap between flanges. However this can govern the type of material which can be
employed, and with it the ultimate performance of the gasket. Thus a resilient
material which could provide good closer with comparatively rough surfaces may

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 40 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 41 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 42 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

extrude at the working pressure required, or not to be compatible with the fluid
involved or the temperature of the service, in which case a finer surface finish
may have to be employed in order to accommodate a harder material with high
closer pressure. With thinner materials it becomes necessary to provide a better
quality surface finish on the metal faces.

Table below gives required surface finish for different types of gaskets.

5.3 Selection of Gasket materials for different services

Fluid Application Gasket material

Steam(high Temp up to 538°C Spiral-wound comp. Asbestos or graphite

pressure)

Steel, corrugated, or plain

Monel, corrugated, or plain

Steam(high Stainless steel 12 to 14 % chromium,

pressure) corrugated

Ingot iron, special ring- type joint

Temp up to 399°C Comp. Asbestos, spiral-wound

Steam(high Temp up to 316°C Woven asbestos, metal asbestos

pressure)

Copper, corrugated or plain

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 43 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Steam(low Temp up to 105°C Red rubber, wire inserted

pressure)

water Hot, medium, and high Black rubber, Red rubber, wire inserted
pressures

Hot, low pressures Brown rubber, cloth inserted

Hot Comp. asbestos

cold Red rubber, Wire inserted, Black rubber, Soft

rubber, Asbestos, Brown rubber, Cloth
inserted

Oils (hot) Temp up to 399°C Comp. asbestos

Temp up to 538°C Ingot iron, special ring-type joint

Oils (cold) Temp up to 100°C Cork or vegetable fiber

Temp up to 149°C Neoprene comp. asbestos

Air Temp up to 399°C Comp. asbestos

Temp up to 105°C Red rubber

Temp up to 538°C Spiral-wound comp. asbestos

Gas Temp up to 538°C Asbestos, metallic

Temp up to 399°C Comp. asbestos

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 44 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Temp up to 316°C Woven asbestos

Temp up to 105°C Red rubber

Acids Hot or cold mineral Comp. Blue asbestos

acids

Woven blue asbestos

Ammonia Temp up to 538°C Asbestos, metallic

Temp up to 371°C Comp. asbestos

Weak solutions Red rubber

Hot Thin asbestos

Cold Sheet lead

6.0 Installation

6.1 Installation and maintenance Tips for all Gaskets: -

All too often we hear “the gasket is leaking”. This is not strictly true. It is the
joint that leaks and the gasket is one component of several that make up the
joint. Unfortunately, the gasket is expected to make up for any and all
deficiencies in design, improper installation procedures and to compensate for all
flange movement due to thermal changes, pressure changes, vibrations etc. In
many cases the gasket will do these things but only when careful attention is
given to all the aspects of gasket selection, design and installation.

6.2 Gasket Installation procedures: -

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 45 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Step 1 Inspect the gasket seating surfaces. Look for tool mark, cracks, scratches or
pitting by corrosion and make sure that the gasket-seating surface is proper for
the type of gasket being used. Radial tool marks on a gasket-seating surface are
virtually impossible to seal regardless of the type gasket being used; therefore
every attempt must be made to minimize these. If remachining of flanges is not
possible, investigate the use of patching cements such as Devcon that can be
fairly effective in repairing the gasket seating surfaces.

Step 2 Inspect the gasket. Make sure the material is as specified, look for any possible
defects or damage in the gasket.

Step 3 Inspect and clean each stud or bolt each nut, each washer, and the facing on
the flanges against which the nuts will rotate. Look for severe galling, pitting,
etc. If any of the above mentioned items are damaged beyond repair, replace
that item.

Step 4 Lubricate all thread contact areas and nut facings. The importance of proper
lubrication cannot be overstressed. No joint should be made up without the
proper lubricant being applied to the threaded surfaces and to the nut facings.
When flanges will be subjected to high temperatures, the use of an anti- seize
compound should be considered to facilitate subsequent disassembly. There are
available on the market today a vast variety of an anti-seize compound should be
considered to facilitate subsequent disassembly. The better the lubricant, the
more consistent will be the actual achieved bolt stress at installation.

Step 5 With raised face and flat face installation, loosely install the stud bolts on the
lower half of the flange. Insert the gasket between the flange facing to allow the

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 46 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

bolts and nuts and bring all to a hand – tight or snug condition. (If the gasket is
being installed in a recess or a groove, center the gasket midway into the recess
or the groove.)

Step 6 Torque bolts in a minimum of four stages as listed in steps 7,8,9 and 10 below.

Step 7 Torque the bolts up to a maximum of thirty percent of the final torque value
required following the sequence recommended. (See charts for bolting
sequence.) Number bolts so that torquing requirements can be followed. With
any gasket material, it is extremely important to follow a proper bolting
sequence. If this sequence is not followed, the flanges can be cocked. Then,
regardless of the amount of subsequent torquing, they are cocked. Then,
regardless of the amount of subsequent torquing, they cannot be brought back
parallel. This problem, of course, is maximized on metallic gaskets more so than
on nonmetallic.

Step 8 Repeat step 7, increasing the torque to approximately 60 percent of the final
torque required.

Step 9 Repeat step8, increasing the torque to the final torque value.

Step 10 On high-pressure, high-temperature applications, it is suggested that the

flanges be retightened to the required stress after 24 hours at operating
pressures and temperatures to compensate for any relaxation or creep that may
have occurred.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 47 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 48 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 49 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

7.0 Trouble - shooting Guide

Fault Cause Remedy

Design

Insufficient gasket Insufficient bolt load Increase number of bolts

stress

Increase Dia of bolts

Change to higher tensile

material

Gasket too thin Fit thicker gasket

Gasket too wide Reduce area of gasket

Wrong gasket type Fit gasket which requires a

lower seating Stress

Excessive gasket stress Excessive bolt load Reduce number of bolts

Change to lower tensile material

Gasket too narrow Increase area of gasket

Wrong gasket type Fit gasket which requires a

higher seating stress

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 50 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

ASSEMBLY

Lack of compression Bolts insufficiently Apply additional torque

tightened

Incorrect tightening Bolts should be tightened in

procedure sequence

Gasket relaxed due to It is recommended that once

operating temperature plant reaches operating temp all
gaskets are ‘followed –up’to
restore compression

Bad threads Ensure nuts are a good running

fit over entire length of bolt
threads

Insufficient length of Ensure threads sufficiently long

thread to allow nuts to make contact
with metal faces

METAL FACES

Uneven Flanges too thin Flanges should always be

sufficiently rigid not to be
destroyed by the bolt loads

The use of an IBC gasket With thin flanges and an IBC

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 51 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

(ring joint) gasket the bolt load could cause

flanges to bow or bend

Flanges should be straightened

and full faced gasket used

Flanges not parallel Flange faces should always be

parallel and bolt load should
never be relied on to pull
flanges together. Please refer to
Fig no --- and no ---below.

Damaged Mechanical damage while Every attention should be given

faces exposed to ensure faces are clean, flat
and free from imperfection too
deep for the gasket material to
completely fill.

Dirty or corroded Previously used jointing Faces should be wire brushed

compounds frequently right down to clean metal.
harden and from an
uneven surface

Serration’
s should also be
perfectly clean and of sound
contour.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 52 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Old gasket not Spigot and recess faces should

completely removed be checked for correct fit

Incorrect surface texture Concentric grooving is ideal for

high pressures.

GASKET MATERIAL

Loss of resilience and Re-use of gasket The re-use of gaskets is not

interface contact recommended

Metal gaskets work Where possible metal gaskets

hardened such as copper should be
annealed prior to use. When
they can give further useful
service.

Material deteriorates Material incompatibility Check manufacturer’

s material
rapidly with contained fluid / recommendations and select a
temperature material or gasket type capable
of withstanding the conditions

Gasket extrudes from Too high a seating stress See recommendations under
faces design faults

Excessive use of jointing Unless specified by gasket

compounds manufacturer the use of
compounds and pastes is not

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 53 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

recommended.

Incorrect dimensions Design or manufacturing Gasket should always have

errors clean cut edges with the bore
slightly larger than that of the
vessel or pipe

Fig no 14

8.0 Troubleshooting Leaking Joints.

Gasket badly corroded select replacement material with improved

Gasket Extruded select replacement material with better cold flow

Excessively
Properties, select replacement material with better load

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 54 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

carrying capacity - i.e., more dense.

Gasket Grossly Crushed Select replacement material with better load carrying
capacity, provide means to prevent crushing the gasket by
use of a stop ring or re-design of flanges.

Gasket mechanically Revise gasket dimensions to insure gaskets are proper size.
damaged due to Make certain gaskets are properly centered in joint.
overhang of raised face
or flange bore.

No apparent gasket Select softer gasket material. Select thicker gasket material.
compression achieved Reduce gasket area to allow higher unit seating loads.

Gasket Substantially Indicative of excessive “flange rotation” or bending. Alter

thinner O.D than I.D. gasket dimensions to move gasket reaction closer to bolts to
minimize bending movement. Provide stiffness to flange by
means of back-up rings. Select soft gasket material to lower
required seating stresses. Reduce gasket area to lower
seating stresses.

Gasket unevenly Improper bolting up procedures followed. Make certain

compressed around proper sequential bolt up procedures are followed.
circumference

Gasket thickness varies Indicative of “ flange bridging” between bolts or warped

periodically around flanges. Provide reinforcing rings for flanges to better
distribute bolt load. Select gasket material with lower

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 55 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

circumference. seating stress. Provide additional bolts if possible to obtain

better load distribution. If flanges are warped remachined or
uses softer material.

Fig no 15

9.0 SEALING LAYER MATERIALS AND SEALING STRESSES

The following table gives information regarding different types of materials

offered as sealing layer materials. Also given is recommended seating stress for
reliable sealing purpose.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 56 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Temp.
Seating Stress
(Deg.C) Max.Oper
Gas
Materi ating Applicatio
tightn Optimu
al Pressure( n Min Max
ess m
Min Max Bar) (N/m (N/mm
(N/mm 2
m2) 2
)
)

Graphi Aggressive
-200 550 250 Good 20 90 400
te Media

Aggressive
PTFE -200 250 100 Good 20 90 400
Media

Modera
CAF -150 450 100 Liquids 65 161 400
te

Aggressive
Silver -200 750 250 Good 125 240 450
Media

9.1 CORE THICKNESS

When a is replacing an existing gasket (eg. spiral wound gasket), It is

recommended that 4mm thick core shall be used to prevent unnecessary
stresses on existing pipelines.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 57 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

For new systems, it is recommend to use 5mm thick cores. This value should be
taken into account of the design stage.

Seated Thickness (Core

Pipe system Core thickness
+ 2 sealing layers)

Existing 4mm 5.0mm to 5.2mm

New 5mm 6.0mm to 6.2mm

9.2 Gaskets consist of a metal core

(Generally Stainless Steel) with concentric grooves on either side with sealing
materials. The sealing layers (depending on the service duty) can be Graphite,
PTFE (Teflon), CAF or Metal (e.g. Aluminum or Silver). Gaskets used without
sealing layers to provide an excellent seal but there is a risk of flange surface
damage.

o The very wide seating stress range (minimum to maximum stress) of the
gasket makes it:

§ Highly suitable for varying temperature and pressures.

§ Less sensitive to assembly faults (inaccurate bolt tensioning).

§ Suitable for light and heavily constructed flanges.

o Dependent on layer material gaskets are resistant to temperatures up to

1000 o C

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 58 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

Resistant to media pressures up to 250 bar.

The additional benefits are:

o When assembled the layer thickness of the sealing material is extremely

small (0.5mm) thus reducing leaks, reject rates and environment
pollution.

o The gasket will not damage the flange surface and can be easily removed.

o Reduces maintenance costs

o Emergency sealing of damaged flanges by using 1mm thick sealing layers

until the flange can be re-worked.

o Flange face protection. Gaskets will not damage the flange faces even at
extreme seating load.

o Excellent performance when subject to fluctuating temperatures and

pressures.

o Direct replacement for existing gaskets. No special flange finish is

necessary.

o Eco-friendly by significant reducing leakage into the atmosphere.

1.0 Do’
s & Don’
ts

10.1 Do’
s

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 59 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

1. Apply additional torque to improve compression on gasket, which avoids

leakages.

2. Bolts should be tightened in sequence i.e. diametrically opposite and

gradually increasing load on each bolt alternately to distribute uniform
load on gasket.

3. Once plant reaches operating temperature all gaskets are “followed-up” to

restore compression.

4. Ensure threads sufficiently long to allow nuts to make contact with metal
faces, which gives uniform compression.

5. Check manufacturer’
s material recommendations and select a gasket,
which is capable of withstanding the conditions.

6. Use better load carrying capacity material.

10.2 Don’
ts

1. The re-use of gaskets is not recommended.

2. Do not select the under size gaskets which will protrude into the flow path
of the fluid and could create turbulence.

3. Do not use of pastes or compounds unless specified by manufacturer,

which reduces the friction between the gasket, and thereby load bearing
properties.

4. Do not use of seating surfaces having cracks, scratches, pitting etc.

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 60 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

5. Do not grease the gasket, as it is incompressible.

11.0 Standards

There are variety of standards that govern dimensions, tolerances and

fabrication of gaskets. The more common international standards are:

11.1 Materials

British

BS 1832 – Specification for oil resistant compressed asbestos fiber jointing.

BS 2815 – Specification for compressed asbestos fiber jointing.

Grade A – For water, inert gases, inert liquids or steam up to 64

bar and 510°c

Grade B – For water, inert gases, inert liquids or steam up to 16

bar and 230°c

German

DIN 3754 – Specification for various compressed asbestos fiber grades.

American

ASTM F104 – Classification system for non- – metallic gasket materials.

11.2 Dimensions

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 61 of 62
SVKR
 RELIANCE GROUP Module No.
Gaskets
TRAINING MODULE RG-CM-G - 001

British

BS 3063 – Dimensions of gaskets for pipe flanges to BS 10, BS 1770 and BS

2035.

BS 4865 – Dimensions of gaskets for pipe flanges to BS 4505, BS 4622 and

BS4722.

Part 1 – Dimensions of non- - metallic gaskets for pressures up to 64

bar.

Part 2 – Dimensions of metallic spiral wound gaskets for pressures 10

to 250 bar.

BS 3381 – Design material and dimensions of metallic spiral wound gaskets for
use with flanges to BS 1560.

American

ASME B16.20 – Dimensions of metallic gaskets for pipe flanges, ring joint, spiral
wound and jacketed

ASME B16.21 – Dimensions of non-metallic flat gaskets for pipe flanges

API 601 – Metallic gasket for piping.

*************************************

Author Rev: 0
RSG / MGC
Approved by Date: 12/13/01 Page 62 of 62
SVKR