Gaskets are meant to provide the proper sealing of two mating surfaces or components. Therefore, they must be installed optimally. With proper installation, the gaskets can easily prevent leakage on the involved components even under varying levels of compression.
The installation of gaskets normally involves a thorough cleaning, inspection, alignment of flanges, lubrication, and many more. If you intend to install gaskets for your select components, here are some of the best practices that you should know and follow.
Proper Cleaning and Inspection
The flange surface must be free from any foreign material or gasket debris. Therefore, you must clean any material that can be found in the sealing face, flange serrations, fasteners, and others with a brass wire brush. Avoid the use of the grinder, hammer, and chisel in removing the foreign material.
As for the inspection, you must ensure that sealing face should not have any dents, dings, mars, or pitting that can cause some issues once the new gasket is installed. If there is a presence of these elements, then repairs might be required. But once it is already defective, then you must replace them right away.
Confirming Gasket Properties
Before installing the gaskets, you must make sure that they have the correct dimensions for your specific applications. You must take note that the inner diameter of your gaskets should not be smaller than the flange’s inner diameter. If you want to simplify the centralisation of the gasket, then you may want to slightly cut the bolt holes. And just like your flange surfaces and other components, your gaskets must also be free from any defects and issues to ensure that they can be installed flawlessly.
Aligning the Flanges Correctly
An effective seal is only possible if the flanges are aligned properly. And with proper alignment of flanges, you can expect to obtain a uniform maximum gasket load that can create the best seal for your components and systems. One thing to remember when aligning the flanges is to avoid the use of a pry bar or screwdriver. Numerous tools can help in the linear and rotational alignment of flanges.
Installing the Gaskets Accordingly
Once the flanges are set and the gaskets are inspected, the gaskets can now be installed to the flanges. You can start the installation by inserting the gasket between the dry flanges and ensuring that it is centred between them. The use of joint compounds or release agents is not recommended for gasket installations unless state otherwise by the gasket manufacturer. Without any recommendation from the manufacturer, the application of joint compounds or release agents can easily cause chemical attacks on the gaskets, which can compromise their core properties and service life.
Lubricating Load Bearing Surfaces
Lubrication is integral to the functions of gaskets, which is why they must be lubricated optimally. Lubrication can help in both the assembly and disassembly of the gaskets. In choosing your lubricant, you must consider the temperature, particle type, and size. The use of high-quality lubricant can easily make the installation successful, especially when the bolt is tightened. The right way of applying lubricant is to spread it evenly to the thread, nut, and washer load-bearing surfaces. Alternatively, the lubricant must not be applied to the gasket or sealing surface.
Once these steps are followed, you can now install and tighten the bolts. You must, however, consult the gasket manufacturer to know the recommended torque values.
Food processing, petrochemical, pharmaceutical, and other industries all utilise the capabilities of gaskets. Gaskets are mechanical seals that can cover the intersection and fill the space between two or more mating surfaces. They are typically made to be flexible so they can effectively withstand vibration, reduce noise, resist chemicals, and provide significant sealing.
Gaskets can be made from different materials. Some of these materials are paper, metal, and copper. Aside from these materials, these sealing components can also be manufactured out of sponge or foam. Sponge and foam are two distinct materials that may be similar in some ways. However, they also have key differences that make them suitable to select applications.
To know more about sponge and foam gasket, then here are some of their qualities and differences.
Sponge gasket materials are made by heat curing certain elements such as neoprene, nitrile, and silicone that would create a closed-cell sponge structure for their overall structure. Numerous compressible air pockets or bubbles are then formed through the expanding process. Manufacturers have the liberty to control the size and distribution of the pores. Nevertheless, their closed cellular structure allows these gaskets to absorb little moisture, withstand extreme temperatures, and resist ultraviolet light and ozone. It also provides gaskets with much-needed vibration isolation and shock resistance qualities.
What is unique about sponge gaskets is that their pores can conveniently affect their overall properties. Compressing sponge gaskets allows them to obtain a strong compression set resistance and superb compression recovery. Additionally, the closed cellular structure of these gaskets can easily block any movement of gases and liquids, making them ideal for heating, ventilation, and air conditioning sealing applications. And even the edge pores of these gaskets are cut and exposed, their body can still serve as a barrier against different surrounding elements.
Unlike sponge gaskets, foam gaskets are known to possess an open cellular structure. The overall structure of foam gaskets comes from the carbon dioxide gas that is created by the chemical reaction in a liquid mixture. The open structure of foam gaskets may look like a mesh, giving these gaskets appropriate stiffness and rigidity. Still, the overall properties of foam gaskets would depend primarily on the type of polymer used. Some types of polymer that are used in creating foam gaskets include polyethylene, polyurethane, and polyvinyl chloride.
Aside from being stiff and rigid, foam gaskets also boast other qualities that make them recommended for a lot of applications. They have a superior barrier and bonding capabilities that are suitable for a wide array of industries such as automotive, medical, electronic, lighting, and many more. Some characteristics that make foam gaskets great for these industries include proper insulation, effective electrical absorption, fluid and noise restriction, and weather resistance. With shock or vibration applications, the best type of gaskets that one should choose would be foam gaskets with open cellular structure. If you need more information about sponge and foam gaskets, then feel free to contact us at Gasketech. We are a manufacturer and supplier of gaskets and sealing washers, extrusions, and mouldings for all industries.
Gaskets are mechanical seals that can fill the spaces between two or more surfaces and prevent them from any leakage incidents. These functionalities of the gaskets alone make them beneficial for a lot of commercial and industrial applications.
A lot of equipment and components that utilise gaskets are made from metals. However, several applications maximise non-metallic materials and devices. Gaskets intended for non-metallic applications must be able to resist pressure and prevent chemicals, fuels, and other substances from leaking in or flowing out. They must also resist corrosion, chemicals, and other elements that might damage them throughout their operations.
Fortunately, there are a lot of material options that can be used as gaskets for non-metallic applications. Most of these materials can effectively withstand the elements that have been previously mentioned.
Fibre gaskets are mainly composed of natural cellulose that is infused with different types of materials such as rubber, insulating fibre, synthetic fibre, and vulcanised fibre. Fibre gaskets are suitable for non-metallic applications that have low to medium temperatures and pressures.
One type of synthetic elastomer is known as ethylene propylene. This type of gaskets is recommended for applications revolving corrosive and hydraulic fluids. They can likewise work under severe weather conditions. This type of gaskets, however, is not suitable for applications that involve oils and fuels.
Mica gaskets are comprised of phlogopite mica paper that is waterproofed with a silicone binder. This type of gaskets is recognised for its good temperature resistance, making it suitable for high-temperature applications. Mica gaskets can be utilised in gas turbines and heat exchangers.
Another material that is part of the elastomer family is nitrile. Nitrile gaskets boast excellent resistance to petroleum products, hydrocarbons, and solvents. They can also effectively withstand tear and abrasion. Nitrile gaskets can be maximised by aerospace, military & defence, and petrochemical industries.
Neoprene gaskets are made from synthetic rubber that can be effective in applications involving water, oil, and other solvents. This type of gaskets is believed to be durable, flexible, resilient, and resistant to compression. They can likewise withstand combustion and extreme weather conditions.
Polytetrafluoroethylene is a synthetic fluoropolymer of tetrafluoroethylene that can effectively resist chemicals and extreme temperatures. This type of gaskets is typically used in food processing, pharmaceutical, petrochemical, and electrical applications.
The material polyurethane is a type of polymer that can give superior load-bearing properties, wear resistance, and rebound capabilities. Gaskets out of this material can easily resist the damaging effects of oxygen, ozone, and grease, which makes them suitable for machine mounts and electrical equipment.
Gaskets that are made from silicone are common today since they can effectively work under high temperatures. They likewise do not react with sunlight and ozone, making them great for outdoor use. Silicone gaskets are typically utilised in food processing and medical applications.
All these mentioned gaskets are great for non-metallic applications. For more information about non-metallic gaskets, just give us a call at Gasketech.
Gaskets are mechanical seals that can fill the space between two or more mating surfaces. These hardware devices are typically installed between two objects so that they can prevent any leakage from or into the objects while they are under compression. They can also effectively cover irregularities and increase the sealing ability of the materials.
Different industries utilise the benefits and capabilities of various types of gaskets. One industry that maximises these hardware devices is the petrochemical or oil and gas industry. This industry typically uses equipment and devices that process oil, gas, water, and many other elements. Any erroneous leaks by these elements can easily affect the operations of the industry. And so, it would only be necessary for the said industry to maximise gaskets for safer and more secure overall operations.
To help you out, here are some of the most common types of gaskets for oil and gas applications.
Non-asbestos gaskets are typically made from organic fibres, aramid fibres, nitrile rubber (NBR), and mineral fibres. They are created with full-face flanges that boast elastomeric properties. Most of these gaskets have high chemical resistance, great compressibility, and a reasonable amount of recovery property if they are not overstressed. These gaskets are typically applied in low-pressure and low-temperature applications, but they can also be used on applications that require chemical resistance.
Another type of gaskets that are being maximised for oil and gas applications is envelope gaskets. These gaskets can possess either double jacketed gaskets or an envelope of polytetrafluoroethylene (PTFE) with an inlay. These gaskets are primarily used as a flange gasket for applications that require high-chemical and high-pressure resistance. They do not, however, have a reasonable amount of compression or recovery. They do not also hold up to radial shear during high-temperature fluctuations.
Ring Type Joint Gaskets
Ring type joint gaskets, alternatively, are machined precisely so that they can be applicable for high-pressure and high-temperature applications. They are normally made from soft stainless steel gasket materials. However, they should be replaced every use due to deformation in their flanges. These gaskets usually come in oval or octagonal shapes, which can be useful for API 6A applications. Some other types of ring joint gaskets must be created in strict accordance with API 17D and ASME B16.20.
Flat Metal Gaskets
Flat metal gaskets are typically made from a stainless steel core and do not have any filler material. Some other flat metal gaskets can likewise be fabricated from aluminium, copper, pure iron, titanium, and others. They can come in a wide variety of sizes and shapes. These gaskets are used in applications that have low criticality, low compressibility, and low recovery. They are not, however, recommended for applications that have both high temperature and pressure.
Spiral Wound Gaskets
Spiral wound gaskets with an inner ring are great for all pressure ratings of pipe flanges. These gaskets are also recommended for heat exchangers due to their sealing ability tolerances, making them great for other high-pressure and high-temperature applications. They also have more compressibility and recovery. The inner ring of these gaskets is usually made from stainless steel, while the outer ring is made from carbon steel.
If you want to know more gaskets for oil and gas applications, feel free to contact us at Gasketech. We manufacture and supply gaskets, washers, extrusions, and mouldings for all types of industries.
Sealing two mating surfaces is typically done by gaskets. These mechanical seals can easily prevent any type of leak from going in and out of the joined objects while under varying levels of compression. One of the objects that can be joined by gaskets is flanges.
Two gaskets that boast great features for sealing materials like flanges are ring-type and full-face gaskets. Each of these gaskets has its own set of features and advantages that can make one of them recommended for certain applications.
Ring-type gaskets do not have any bolt holes, making them suitable for raised face flanges. Raised face flanges are the most common type of flanges that are maximised in process plants. The gasket surfaces of these flanges are raised above the bolting circle face, allowing them to use a wide variety of gasket types and designs. This type of flange can effectively divert more pressure on a smaller gasket area. As the pressure increases in the given area, the pressure containment capability of the joint then increases.
The installation of the ring-type gaskets is simple. They are typically installed inside of the flange bolts and around the pipe bore. These gaskets can be effectively assembled right on top of the flange without taking the joint apart. The dimensions needed when purchasing ring-type gaskets are the inside diameter that matches the pipe bore, the outside diameter that complements the flange face’s outside diameter, and the thickness of the whole gasket.
One great thing about ring-type gaskets is that they require less material for them to be fabricated. Additionally, they require less cutting.
Most applications that utilise flat face flanges are related to the mating flange that is made from a casting. The positioning of the gasket surface and the bolting circle face of this flange type allows full-face gaskets to fully cover the entire face of the flange, which then eliminates the need for the flanges to be bolted to a raised face flange. The use of full-face gaskets for flat face flanges allows them to be sealed tightly.
Covering the entire face of the flange means that the full-face gaskets will certainly possess the flange’s outer diameter measurement. All necessary holes that will secure the bolts can also be found on this type of gasket, ensuring that the gasket positioning will be much easier. The number of the bolt holes, the bolt circle diameter, thickness, pressure tolerance, and the inside and outside diameters are often requested when requesting for full-face gaskets.
Full-face gaskets can be installed easily due to the presence of bolt holes. The joint, however, should be disassembled first before installing the gaskets. The interior and exterior diameters of the gaskets, as well as the spacing between bolt holes and the flange, must be correct to maximise these gaskets. If you want to know more about these types of gaskets, feel free to contact us at Gasketech. We manufacture and supply gaskets, washers, extrusions, and mouldings for all types of industries.