13 - Jesse Meisterling Gaskets and Leaks PVRC Recommendations and Studies

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Copyright Copyright The Augustus Group 2006 The Augustus Group 2006
GASKETS AND LEAKS:
PVRC STUDIES AND
RECOMMENDATIONS
Jesse Meisterling
A Gasket Is A Replaceable Element That Must
Create And Maintain A Tight Seal Between
Flange Faces. Gaskets Must Allow For
Repeated Make/Break Cycles For System
Maintenance, Eliminate Need For Perfect Joint
Contact Surfaces, Yield Or Flow Into
Imperfections To Effect Seal
GASKETS: A DEFINITION
GASKETS: PROPERTIES
Sealability; resistance to fluid passage
Elevated temperature properties; resists
thermal degradation
Contained fluid resistance
Deforms under compression; yields into
crevices
Minimum time dependant creep in service
Won't crush under system loads
Will recover (elastic) with loss in bolt load
JOINT TYPES
Raised Face Flat Face
Tongue and Groove Ring Joint
GASKET TYPES
SELF-ENERGIZING GASKETS
CODE BOLTING
REQUIREMENTS
Mandatory Appendix II
-" y" + " m" factors used to size bolts
- y --- Initial gasket seating stress
- m --- Maintenance factor for operating conditions
Assembly: Non-mandatory Appendix S
Design loads may not seal
Higher bolt loads are allowable provided joint (gasket) not
damaged
Consider preload control when necessary
Quality Assurance
General provisions of subsection NA
FLANGE FACE
FINISH RECOMMENDATIONS
Type of Gasket Surface finish
(AARH)
Surface finish range
(AARH)
Spiral wound 125 l00-125
Teflon Serrated* (500+) 500-1000
Filled Teflons 200 125-250
Expanded Teflons 200 125-250
Compressed sheet (old) Serrated* (500+) 500-1000
Compressed sheet (new) 250 125-250
Flexable graphite 250 125-250
O-ring (metal) 63 32-63
Oval ring/delta ring 63
63
Double Jacketed 80 63-80
Metal ring (solid. flat) 80 63-80
SURFACE TOLERANCES
Flatness Tolerance at Flange Gasket Contact Surface
For all ASME flanges 'both radial and circumferential directions,
shall be 0.006 inch (0.15 mm) total indicator reading...'
RING JOINTS
Ring Grooves: Finish-32, Angle-15', Groove Pitch
Run-out 0.007"
ANGULAR MISALIGNMENT
Angular misalignment at the coupling surface shall be less than
0.002 per inch of NPS, with a maximum of 0.030 inch (example: 4
inch pipe x 0.002 = 0.008 inch). Pipes under 3 inch NPS allow 0.008
inch with limit of 0.020 inch.
Parallel offset
For flanges smaller than 10 inch NPS = 1/16 inch
For flanges greater or equal to 10 inch = 1/8 inch
CASE STUDY
Problem 48" reboiler: 1 B7 Studs.
Reboiler design with the tubesheet
sandwiched between the flanges
CASE STUDY
Finite Element Abacus Model Was Developed By Stevens
Institute And Checked Against Operational Data.
CASE STUDY
FEA Model Over
Temperature And
Pressure
A
B
B
A D
C
C
E
D
E
100
200
400
300
25
20
15
10
5
Bolt Load
Gasket Stress
at ID
Gasket Stress
at OD
Flange Internal
Bolt
30
10
20
40
Bolt
Stress
KSI
Gasket
Stress
KSI
Deg F
CASE STUDY
Bolt Stretch Variability After Third And Normally Final Pass
Using Torque
CASE STUDY
Bolt Stretch Variability After Using Ultrasonic Extensometer
LEAK RATE DEVELOPMENT TEST RIG
Bolt load measurement
ANSI STD flange (6")
Seal Plate
Opening for annular space pressure
connection
"O-ring" 2 places
Test Gasket
Annular Space
Gasket Stress Strain Behavior Relative
Stress Strain Loading/Unloading Curve For
Gasket Materials
PVRC BASED RULES
LEAK
RATE
AND
STRESS
PVRC BASED RULES
LEAK RATE AND
MATERIALS
Graphite Sheets In
0.015 Inch And
0.063-inch
Thicknesses, As
Well As 0.063-inch
Metal Reinforced
Graphite Sheet
Were Tested
Against Spiral
Wound Asbestos
(Water At 120 psi
And 500F).
PVRC BASED RULES
LEAK RATE OF GRAPHITE AND ASBESTOS
Leak Rate (Water)
Vs. Compressed
Thickness Of
Asbestos And
Graphite 4" SW
Gaskets At 125psi,
550F At 500hr.
10-4
10-5
10-6
10-1
L
E
A
K
R
A
T
E
ml
/s
2.2 2.4 2.6 2.8
Compression Thickness - mm
PVRC BASED RULES
SEATING STRESS, OPERATIONAL STRESS AND
LEAK RATE
The Leak Rate Of A
Gasket Joint Is
Dependant On The
Both The Initial Seating
Stress (Preload) And
The Operational Stress
Level.
PVRC BASED RULES
LOADING LIFE OF A GASKET
A Fixed Compression System Experiencing The Same Amount
Of Creep Will Have A Higher Leak Rate Due To The Lower
Operational Stress
Live Loading
1. Live Loading
2. Fixed Compression
3. Free Compression
PVRC BASED RULES
COMPRESSION CHARACTERISTICS
Compression
Characteristics
Of 4" Spiral-
wound
Asbestos
Gaskets
2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5
Psi
(mpA)
14.5
(100)
11.6
(80)
8.7
(60)
5.8
(40)
2.9
(20)
-------- 4A-1
........ 4A-2
-- - - - - 4A-3
Spiral-wound asbestos
PVRC BASED RULES
COMPRESSION CHARACTERISTICS
It Is Important To Note
The Variation In The
Compressed
Thickness At A Target
Stress. This Is Important
When Working With
" Constant Deflection"
Flanges And Gaskets
-------- 4G-1
........ 4G-2
-- - - - - 4G-3
2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5
Psi
(mpA)
14.5
(100)
11.6
(80)
8.7
(60)
5.8
(40)
2.9
(20)
Spiral-wound Graphite
PVRC BASED RULES
THERMAL CYCLING
PVRC SWA Relaxation Plot From Test Data
Thermally induced
gasket load cycles
coupled with reloading
hysteresis behavior
'ratchets' stress out of
system with every load
cycle.
PVRC BASED RULES
Mass Leak Rate Vs.
Gasket Stress For
Spiral Wound
Asbestos
PVRC BASED RULES
Gasket Materials Can Now Be Standardized By Leak Rate
With The ROTT Procedure
Room Temperature Tightness Test
Gasket Stress And Leak Rate Data Taken For A Gasket Material
At Different Operating Pressures
Standard Gasket Properties Are Developed:
Tp
Gs
Gb
A
PVRC BASED RULES
Leak Rate Performance from Gasket Test Data
Tightness Parameter (Tp) is a non-dimensional leakage-pressure
relationship. Tp expresses the pressure (in atm) required to produce
a unit gas leak rate (L=L*=1mg/s); a higher value of Tp implies a
tighter joint.
Tp= (p/p*)[L*/L]
a
Exponent a (for most gases) is 0.5; an increase in 10 for Tp is
equivalent to decrease of 100 in leak rate. Plotting gasket stress, Sg
as a function of Tp (log/log) is a graphic representation of gasket
performance over a range of applied (operational) stress.
PVRC BASED RULES
Leak Rate Performance from Gasket Test Data
Tp= (p/p*)[L*/L]
a
p* = 1 ATM Pressure
p = Test Gage Pressure
L* = Standard Leak Rate, 1mg He/s/150 mm
L = Measured Leak Rate, mg/s/mm
PVRC BASED RULES
Gasket Stress Vs
Tightness
Parameter For
Spiral Wound
Asbestos
PVRC BASED RULES
Typical Plot Of
Gasket Stress
Vs. Gasket
Deflection With
Constant Tp
Lines For Spiral
Wound
Asbestos
PVRC BASED RULES
Plot Of Gasket
Stress Vs Gasket
Deflection With
Constant Tp
Lines For Spiral
Wound Graphite
PVRC BASED RULES
Breakout Of
Tp=500 And
Assembly
And Min.
Operating
Stress
PVRC BASED RULES
Development of PVRC Gasket Parameters from ROTT
PVRC BASED RULES
Development of PVRC Gasket Parameters from ROTT
PVRC BASED RULES
PVRC BASED RULES
PVRC BASED RULES
Design for tightness
Tightness Parameter
Tp= (p/p*)[L*/L]
a
Minimum Required Tightness
TpMin = 0.1243(Tc) P
Minimum Required Cold Boltup Gasket Stress
Sya = (Gb/n) (Tpa)
a
Minimum Required Operating Gasket Stress
Sm1 = Gs (TpMin)
k
k = Log (n Sya / Gs) / Log (Tpa)
PVRC BASED RULES

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