ENGINEER MUHAMMAD REHAN

Pre Test 1. What is a Gasket 2. How Gasket Prevent leakage 3. Gasket Specifications 4. Sizes of Gasket 5. Materials of Gasket 6. Temperature-Pressure rating of Gasket 7. Types of Gasket 8. Selection of Gasket 9. Piping Services at EPCL Plant 10. Gaskets used at EPCL Plant 11. Piping Specification at EPCL Plant 12. Installation of Gasket 13. Precautions for Gasket 14. Loss due to Gasket Leakage 15. Gasket Leaks Incidents Post Test Questions can be asked anytime throughout the Training

 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 temperatures.

 Does Two flanges seal without gasket?  If Yes then Why?  If No then Why not?

SPECIFICATIONSEXAMPLE Type of GasketFull Face Gasket MaterialEPDM Size3” (Vary from ½” to 24”) Temperature- Pressure rating150# (Vary from Class) StandardB16.21 (Non-metallic Flat Gaskets for Pipe Flanges)

 ½ “ -24”  As per application

 Will be discuss along with types

 ASME Pressure Classes:  Class 150 means this Gasket can sustain up to 150 psi maximum if the service temperature is around 550F.  Maximum working pressure increases with decrease in temperature  At 100F service temperature, the gasket can sustain 285 psi

7.1 Metallic 7.2 Semi Metallic 7.3 Non metallic 7.4 Liquid Gasket or Sealant

7.1.1 Solid Metal Ring Hollow Metal O- Ring Corrugated Metal

 Shape: Octagonal and Oval  Size: R, RX or BX number  Material: SS- 304/316/321/347/410/F-5, Soft iron ‘D’, Hasteloy Inconel & Monel  Maximum P-T rating: Class  Standard: ASME B16.20  Application: Flanges of ASME B 16.5, ASME B 16.47, or API Specification 6A).

 Material: Various grades of Inconel and Stainless Steel  Maximum Pressure: High Vacuum to 700MPa  Maximum Temperature: Cryogenic to 1000C  Application: Mechanical Seals

 Material: Soft aluminum, copper or brass, Metal Iron or soft steel, Inconel, Monel, SS304/ 316L  Maximum T-P rating: Class  Application: Valves, Pumps, Heat Exchangers, Flanges, Vessels

 Spiral Wound  Jacketed Metal Gasket

 Application: Flanges of ASME B16.5 & B16.47  Standard: ASME B16.20

 Maximum P-T rating: Class  Application: Heat exchangers, Boilers and flues, Autoclaves and other pressure vessels. Gas mains, Pumps, Valve bonnets and duties involving high temperature and dry heat.

 Rubber Gaskets  Graphite Sheet Gasket  PTFE Sheet Gasket  Compressed Joint Sheet Gasket  Sealant Tapes

 Material: i. Natural Rubber (-70F – 200F) ii. Styrene Butadiene Rubber (SBR) (-65F – 250F) iii. Chloroprene Rubber (Neoprene ®) (-60F – 250F) iv. Nitrile Butadiene Rubber (NBR) (-60F – 250F) v. Flouro carbon rubber (FKM) Viton ® (-15F – 450F) vi. CHLOROSULFONATED POLYETHELENE RUBBER (CSM) Hypalon® (50F – 275F) vii. SILICONE RUBBER (VMQ) (-65F -500F) viii. ETHYLENE PROPYLENE DIENE RUBBER (EPDM) (-70F-350F)  Maximum Pressure: 150psi

Material: Graphite with/ without metal inserts Maximum Pressure: upto 250 Kg-F/cm2 Maximum Temperature: C

 Material: PTFE  Maximum Pressure: up to 124Kg-F/cm2  Maximum Temperature: C  Application: Virtually pH 0-14

 Material: Asbestos, non-Asbestos and Fibre  Maximum Pressure: up to 100 Kg-F/cm2  Maximum Temperature: C

 Material: PTFE, rubber, etc

Material: Silicon RTV Maximum Temperature: -59C-329C

TAMP  Temperature  Application  Material  Pressure

 Cooling Water, Waste Water, Boiler Feed Water, Raw Water, Demin & Polish Water  High and Low Pressure Steam, Condensate  Chlorine, HYPO, Hydrogen, Brine  HCl, H2SO4, Caustic  EDC, VCM, Vent Gases  PVC Slurry  Various Catalyst, reactants, agents, etc

 Spiral Wound  Ring Type Joint  Non Asbestos  PTFE  Graphite  Rubber Sheets  Metal Jacketed  RTV  PTFE / Graphite Tapes

 PVC 1 /UTY 1 = TOYO SPECS  PVC 2/ CA/ UTY 2/ PP = CHINESE SPECS  CA Electrolyzer = AKCC SPECS  EDC/ VCM = FURMOSA SPECS

 Flange face cleaning  Flange face inspection  Flange alignment inspection

 Gasket Inspection  Gasket Placement

 Bolts lubrication  Bolts tightening

 On 24 th May 2004, A Hydrogen Fire took place due to the Installation of an Incorrectly Sized Gasket at a Solvent Manufacturing Plant  On 10 th January 2000, approximately 100 barrels of jet fuel were discharged from Plantation Pipeline in Newington, Virginia, resulted from a failed gasket on an interface detector  On 22 nd February 2003, approximately 788 barrels of gasoline were discharged from a portion of Plantation Pipeline in Hull, Georgia, resulted from a failed gasket on a buried block valve.  On 15 th December 2004, Employees were performing maintenance on a propane pipeline near Mantador, North Dakota, when a gasket on the pipeline's valve failed, causing a leak. Nearby resident were evacuated, and a rail line was shut down temporarily. There were no injuries

 Box up Certificate  Signing of Flanges

 Can you use a 150# Class Flange with Steam service Pressure 250psi and Temperature 300F?  What would be the maximum Pressure that a 600# Class flange can bear at 800F?

 You have a purchase an Octagonal ring. What specifications you should send to the vendor if you know the following: i. Material: SS 304 ii. Avg. Pitch diameter of ring: 11.0“ iii. Height of ring: 1.06” iv. Width of ring: 0.875”

 What would be the material of Metallic windings if Outer ring color is: i. Brown ii. Orange iii. Green iv. Blue v. Red vi. Yellow

 What would be the material of filler If the color of the marking on the outer edge of outer ring is i. White ii. Grey

 On what dimensions you will cut a rubber gasket for a Raised face Flange of 3” 150#  On what dimensions you will cut a PTFE Gasket for a Flat Face Flange of 2” 300#

 What are the two ASME Standards for Metallic and non-metallic Gaskets?  For Metallic:  For Non-Metallic:

 Which one is not required in Gasket Selection? i. Temperature of service ii. Size of flange iii. Pipe Internal Diameter iv. Service Compatibility

 Which gasket should we use if the piping specification of a Chlorine Line is G1FF1?  Which gasket should we use if the piping specification of a Chlorine Line is A5S?

 Torquing of Bolts should be done in …… steps?

 Write down the steps involved in Gasket Installation? i. Flange face cleaning ii. Flange face inspection iii. Flange alignment inspection iv. Gasket Inspection v. Gasket Installation vi. Bolts lubrication vii. Bolts tightening