Category Archives: gasketing

Enhanced Surface Profiles for Gaskets

How this feature can improve performance and efficiency with gaskets

Gaskets have always been part of industrial production. However, gaskets have not always been forgiving, easy to use or simple to remove. What if the sealing products were designed to optimize the work put into them? What if the design had a level of intelligence built in? What if the design could make up for equipment damage? When used properly, enhanced surface profiles for gaskets can reduce leaks, spills and other releases that can damage the environment, put people at risk, result in fines and lead to costly downtime.

Using surface profiling to reduce area and increase stress is found in everyday life, from the soles of running shoes to the treads on vehicle tires. Reducing the contact area while maintaining compressive force results in increased stress. In the case of gaskets, traction or friction between a gasket and the flange faces is critical to holding internal pressure. If the downward force created by the fasteners in a flange is diluted or spread over a larger area, the overall stress is reduced.

Compressibility

Adding raised features to the surface of a gasket to reduce contact area and increase stress also tends to impact compressibility. Compressibility represents the ability of the gasket to conform to the surfaces it is being used to seal. Flange surfaces usually show signs of wear, pitting, scratches or other defects. It is cost-prohibitive to make two mating flange faces smooth and flat enough to seal without a gasket. The more compressible a gasket is, the better chance the user has of attaining an effective seal.

picture showing different gasket views
Image 1. (clockwise left to right) Traditional material sees heavier load around the gasket bolts and lighter load farther from the bolts. Image 2. Load distributed more evenly. Image 3. More stress toward the bolts. Image 4. Stress spread evenly around the gasket. (Images courtesy of Garlock)

Pressure Resistance

Compressibility also impacts the amount of pressure exposure on the gasket. When a flange assembly is pressurized, the internal media pushes outward on the inner diameter of the gasket. The thinner a gasket becomes, the less outward force it sees from internal pressure. This is referred to as improved “blowout resistance.” Unfortunately, one common error made when a gasket blows out is to replace it with a thicker gasket. This puts more gasket surface in the pipe or vessel for the internal pressure to act on.

Sealability

To create an effective seal, there are two functions the gasket must accomplish.

First, it needs to conform to the flange face to prevent the media from passing between itself and the flange faces. This is where the compressibility is important. Continue reading Enhanced Surface Profiles for Gaskets

The Lifespan of a Gasket

The Dreaded Gasket Blowout Call

Have you ever received the dreaded 2 a.m. call from plant staff saying that things are at a standstill – production is down?

You arrive at the plant, walk through the parking lot, coffee in hand, and head to the locker room. When you come out on to the plant floor, there are several people staring at you with a look of panic on their faces as steam or process chemical sprays from a pipe flange.

Prognosis……gasket blowout.

You think to yourself “didn’t we just replace that gasket?”, or perhaps “we should have replaced it during the last shutdown but chose not to because of time constraints or cost cutting.

If this scenario is new to you, you are lucky and you can go back to sleep… the 2 a.m. call was a wrong number. If it’s not new to you, this means you are most likely a Plant Supervisor, Maintenance Manager or Plant Personnel in some capacity.

Roll up your sleeves, grab your torque wrench and let’s get to work!

Gasket Lifespan

Picture of NSF Compliant GasketsIf I had a nickel for every time someone asked me, “How long will my gasket last?” I would be a rich man. As you can probably guess, “How long will my gasket last?” is a loaded question to which the practical, factual, and political answer is… an Application Engineer’s nightmare!

A gasket may last 5 years, or it could last 20 years. I cannot give you an exact date or lifespan of a gasket; however I can give you some insight into factors that will give your gasket the best chance at a long and prosperous life between the flanges.

Continue reading The Lifespan of a Gasket

Fried Snack Foods and GYLON® Style 3504 Gasket

Fried Snack Foods and GYLON® Style 3504 Gasket

The GYLON Style 3504 gasket is made of PTFE with aluminosilicate microspheres. It is designed for use in moderate concentrations of acids, caustics, hydrocarbons, refrigerants, and more.

It provides a tight seal, improved performance over conventional PTFE, reduced product loss and emissions, reduced creep relaxtion, excellent bolt torque retention, it doesn’t burn, will not support bacterial growth, plus many more benefits.

INDUSTRY

Food Processing – Fried Snack Foods

CUSTOMER

A major diversified food & beverage manufacturer, with facilities located in all regions across the globe.

BACKGROUND

The customer had persistent problems when sealing hot oil applications on its bulk snack food fryers across several production sites. Build-up of polymerised vegetable oil on the flanges caused unsightly mess, maintenance complications, financial implications, and posed a significant fire risk.

CHALLENGES FACED

As well as ensuring that the sealing material was compliant to FDA and EN1935 standards, the challenge was to ensure that the gaskets would perform well under the difficult conditions presented by the high oil temperatures. Additionally, because the production line was also subject to regular and aggressive cleaning cycles, the gasket material was required to be compatible with other aggressive chemicals across a broad pH range.

Continue reading Fried Snack Foods and GYLON® Style 3504 Gasket

Pipe Gaskets for Diverse Flange Materials

Looking to consolidate your inventory into as few materials or parts as possible?  Would eliminating the installation of incorrect gasketing material interest you?  GORE® Universal Pipe Gaskets may be the answer.

GORE Universal Pipe Gaskets (UPG)GORE® Universal Pipe Gaskets (Style 800) provide a reliable seal for steel, glass-lined steel and fiber reinforced plastic (FRP) flanges, in the full spectrum of strong acid, alkali, and solvent process media, including the most challenging thermal cycling and elevated temperature applications. This single gasket solution can reduce the process safety and production downtime risks caused by the use of an incorrect gasket material. The highly conformable 100% ePTFE also reliably seals irregular surfaces.

Continue reading Pipe Gaskets for Diverse Flange Materials

Case Study: Eliminating Epoxy Use on Flanges

GYLON EPIX™ is a family of gaskets that effectively seals a broader range of applications and is more forgiving during the installation process.  It allows the end user to save valuable turn-around time, reduce re-work, and lower costs, helping them to finish ahead of schedule and under budget.

GYLON EPIX™ features a hexagonal surface profile that provides the torque retention and blowout resistance of a thin gasket and the conformability of a thicker gasket.  GYLON EPIX™ Style 3504 EPX is a high performance, aluminosilicate microsphere filled PTFE sheet material designed for use in moderate concentrations of acids, and caustics, as well as hydrocarbons, refrigerants, and more.

EPIX™ - Phosphate Plant

INDUSTRY

Chemical

CUSTOMER

Phosphate Processor

Continue reading Case Study: Eliminating Epoxy Use on Flanges

GYLON EPIX™ Reduces Gasket Installation Issues

GYLON EPIX™ is a newly developed family of PTFE gaskets. It is manufactured using a patented, profiled surface based on our proven Fawn, Off-White, and Blue GYLON® to create highly conformable materials for optimum sealing performance.

Watch the video below to learn more about GYLON EPIX™, and how it’s patented
hexagonal surface profile can help you reduce gasket installation issues.

GYLON EPIX™ will provide superior functional performance by combining the traditional attributes of GYLON® with an innovative surface design. It offers a broader range of applications than traditional PTFE gaskets that are used in worn and pitted flanges. In addition, this evolutionary material delivers the tight sealing and load retention properties of 1/16” (1.6mm) and the conformability of 1/8” (3.2mm). The hexagonal profile provides GYLON EPIX™ - 3504 EPXimproved compressibility and recovery. The profiled surface reduces the contact area during initial compression to concentrate the compressive force of the flange for improved sealability.

Designed for increased compressibility, GYLON EPIX™ improves performance in misaligned flanges. The consolidation of two thicknesses to one reduces the need to inventory multiple thicknesses. Garlock is dedicated to providing real sealing solutions that meet real world sealing needs. With an improved design, color-coded materials, and single thickness, GYLON EPIX™ makes sealing easier.

For additional information about specific GYLON EPIX™ products:

GYLON EPIX™ Style 3500 EPX

GYLON EPIX™ Style 3504 EPX

GYLON EPIX™ Style 3510 EPX

Case Study: GYLON EPIX™ 3504 EPX

GYLON EPIX™ - 3504 EPXGYLON EPIX™ is a family of gaskets that effectively seals a broader range of applications and is more forgiving during the installation process.  It allows the end user to save valuable turn-around time, reduce re-work, and lower costs, helping them to finish ahead of schedule and under budget.

GYLON EPIX™ features a hexagonal surface profile that provides the torque retention and blowout resistance of a thin gasket and the conformability of a thicker gasket.  GYLON EPIX™ Style 3504 EPX is a high performance, aluminosilicate microsphere filled PTFE sheet material designed for use in moderate concentrations of acids, and caustics, as well as hydrocarbons, refrigerants, and more.


INDUSTRY

Material Processor

CUSTOMER

Cement Manufacturer

BACKGROUND

The customer experienced gasket leaks in their piping system.  This caused lost time due to repairs and clean-up efforts.

CHALLENGES FACED

Several issues that plagued the system – abrasive media stream caused gasket and flange erosion, and low strength bolts prevented the customer from using higher performance gasketing materials that require higher assembly stresses to properly seal.

GYLON EPIX™ 3504 EPX

OPERATING CONDITIONS

  • Media: Dry Cement
  • Temperature: 185°F (85°C)
  • Pressure: 102 psig (7 bar)
  • Class 150 Raised Face Flanges
  • Grade 2 Bolts (low strengths, 57ksi yield strength)

SOLUTION AND BENEFITS

The customer’s desire to have a sealing solution that could work with flanges in their current condition, as well as the lower strength bolt led to the evaluation of the GYLON EPIX™ 3504 EPX in a 6″ 150# raised face flange.  The 3504 EPX gasket effectively seals the damaged flange faces with the lower strength SAE Grade 2 bolts.


Gallagher is your source for all of your Garlock sealing needs.  If you have further questions regarding the GYLON EPIX™ 3504 EPX, or any other Garlock products, please do not hesitate to contact us. Our engineering department is always ready to help you design a sealing solution to your toughest application!

Introducing Garlock GYLON EPIX™

In a world where we are bombarded with the belief that “more is better”, sealing science contradicts that theory with facts that show “thinner is better” when it comes to gaskets, as they provide improved load retention, pressure resistance and sealability. Yet thicker gaskets have their place for uneven, worn or damaged sealing surfaces. So how does a person make the right choice? What if there was a product that could do both?

Now there is…

GYLON EPIX™ is a family of gaskets that effectively seals a broader range of applications and is more forgiving during the installation process. GYLON EPIX™ allows the end user to save valuable turnaround time, reduce re-work, and lower costs, helping them to finish ahead of schedule and under budget.

Garlock GYLON EPIX™The innovative GYLON EPIX™, provides superior functional performance by combining the traditional attributes of GYLON® with an innovative surface design. It offers a broader range of applications than traditional PTFE gaskets used in worn and pitted flanges. In addition, GYLON EPIX™ delivers the sealing and load retention properties of 1/16” and the conformability of 1/8”. The hexagonal profile provides improved compressibility and recovery. The profiled surface reduces the contact area during initial compression to concentrate the compressive force of the flange for improved sealability.

Continue reading Introducing Garlock GYLON EPIX™

The Importance of Flange Gasket Storage

Flange gasket storage is often an after-thought for many of our customers.  While incorrect gasket installation procedures is the #1 culprit when it comes to gasket failure, gasket storage can play a large role in the quality of the gasket being installed.

The following article first appeared in Pumps & Systems Magazine on December 14, 2017.


Get the Most Out of Your Flange Gaskets

Performance Depends on Many Factors

by Laverne Fernandes

Flange gaskets are highly engineered products, and their performance depends on many factors. Certainly design, manufacture, installation, and process conditions are all critical, but so is storage before use. Gasket materials often remain in storage for a long time before they are placed into service. Unfortunately, storage practices for gasket materials are generally not optimal or controlled well enough. This article provides guidance for the storage of different gasket materials to preserve their integrity.

Non-metallic Gasket Material - Gasket StorageGasket materials are divided into three main categories: non-metallic, semi-metallic and metallic. Non-metallic gaskets, or soft gaskets, are fabricated from materials such as rubber, fiber, polytetrafluoroethylene (PTFE) and graphite. The material properties make them ideal for flat-faced applications with low pressures. Metallic gaskets are fabricated from one or a combination of metals. Semi-metallic gaskets are composed of metal and non-metallic materials. The metal is intended to offer strength and resilience while the non-metallic components provide conformability and sealabililty. These types of gasket are used in higher-pressure applications. The most common semi-metallic gaskets are spiral wound gaskets.

Continue reading The Importance of Flange Gasket Storage

Isolation Gasket Solutions from Thermoseal

KLINGERSIL® C-7400 Isolation Gaskets

Application Overview:

Some applications in plants call out for isolation kits to maintain the integrity and reliability of a pipeline and piping system. Isolation kits are designed to work in conjunction with flanges, gaskets, and/or bolt sleeves and washers by eliminating metal-to-metal contact and halting static electric currents. At times they are relied upon for critical applications in severe temperatures and conditions.

KLINGERSIL C-7400 - Isolation Gaskets replace Isolation Kits

The Problem: 

Industry’s first choice are phenolic gaskets. They are often supplied in kits, but they are hard and typically take a lot of load to seal. And lack of load is the number one reason for gasket failure.

Continue reading Isolation Gasket Solutions from Thermoseal