1

In Partnership
THE PIPING JOINT HANDBOOK
Introduction
This booklet has been written as an introduction to and a source of general
information on pipe joints.
2
The flanged joint appears deceptively simple but in fact the science of flanges
and joint sealing is complex and continuously developing. Sound joints are
critical to piping integrity and plant safety.
A pipe joint thus relies on the skill and application of the fitter who puts it
together. orrect selection of materials! application of procedures! correct use of
tools combined with the fitter"s skill are all re#uired to ensure a joint of maximum
integrity.
$ut mistakes have happened% choosing the wrong gaskets! using the wrong
studbolts. Such mistakes cannot be ignored.
The purpose of this booklet is therefore to increase understanding about pipe
joints% from pipe specifications and how to use them! to studbolts and how to
identify them. &ith increased awareness and knowledge it is intended that
mistakes will be prevented.
Technical Data - Compan !
National "tandards
BP En#ineerin# "tandards The following $' Standards are
relevant to pipe flanged joints(
G" $%& - ' )askets and *ointing.
(P %& - & $olting for +langed *oints ,inch Series-
G" $%& - % +langes
G" $%& - ) +ittings.
AN"I * API "tandards. The following American Standards are
used for the standardi.ation of pipe joints(
AN"I Bl+$ /nified 0nch Screw Threads , /1 and /1 2 Thread +orm -
AN"I Bl+&,+$ 'ipe Threads. )eneral 'urpose , 0nch -
AN"I B$-+) 'ipe +langes and +langed +ittings.
AN"I B$-+. +actory made &rought Steel $utt &elding +ittings.
AN"I B$-+$$ +orged Steel +ittings! Socket &elding and Threaded
AN"I B$-+&, 2ing3*oint )askets and )rooves for Steel 'ipe +langes.
4
AN"I B$-+&$ 1on35etallic +lat )askets for 'ipe +langes.
API -,$ 5etallic )askets for 2+ 'ipe +langes and +langed
onnections.
API -A Specification for &ellhead and hristmas Tree 6#uip.
British "tandards The following $ritish Standards are also used for
the standardi.ation of pipe joints.
B" $)-, Steel 'ipe +langes and +langed +ittings.
B" //0$ 5etallic S7& )askets for use with +langes to $S 189:.
B" $0/& ;il 2esistant ompressed Asbestos +ibre *ointing.
B" 1$&) 2ubber $onded ompressed Asbestos +ibre *ointing.
B" /&./ 7Steel pipe flanges ,over 2<= 1$- for the pet7industry
B" /'.. Steel pipe fittings! screwed > soc7welded for the pet7 ind
B" $)0, Specification for /nified Screw Threads.
Pipin# "peci2ications
The 'iping Specification is a document prepared during the design phase of any
project. 0t provides the appropriate selection! specification and material grade of
pipe and piping components for a given service.
+or all subse#uent maintenance and repair on a section of pipe! the piping
specification remains as the key to correct material selection.
BE1O(E CO33ENCING AN4 JOB5 (E1E(ENCE TO THE PIPING
"PECI1ICATION I" E""ENTIA6 TO "PECI14 AND 7"E THE CO((ECT
3ATE(IA6"+ 1O( THE JOB CHECK THAT 4O7 A(E 7"ING THE 6ATE"T
(E8I"ION O1 THE "PECI1ICATION+
DO NOT (E64 ON 9:HAT :A" IN"TA66ED BE1O(E 37"T BE (IGHT; A"
THI" I" NOT A6:A4" THE CA"E< I1 A DI"C(EPANC4 I" 1O7ND5 IT
"HO76D BE (EPO(TED+
1ote that a piping specification only applies to the defined plant! site or
installation. +orties! 5agnus! ?imiington Terminal for example each have their
own piping specifications and they are 1;T interchangeable.
To use the piping specification! reference must first be made to the 'rocess and
0nstrument ?iagram. 0dentify the section of pipe in the '>0? and a line number
will be #uoted. e.g.
0; - :1 - $,,' - $A$E =hich is interpreted as 2ollo=s>
0;
The nominal pipe si.e of the line.
<
:1
The service code. This refers to the contents of the pipe!
in this instance &+ refers to +ire &ater.
$,,'
The pipeline number which is a uni#ue number allocated
to a specific section or run of pipe during the design
stages.
$A$E
The pipin# speci2ication num?er+ This is a short3hand
reference in the piping specification document! and is also
uni#ue to that document.
The letter normally refers to the pressure rating of the
system.
@aving determined the piping specification number! turn to the appropriate page
in the piping specification document. There the correct type of gasket! the
correct grade of studbolts! spectacle blinds! blind flanges! pipe material! pipe
wall thickness and much more will be specified for the job in hand!
Pipeline 1lan#es
There are numerous types of flanges available. The type and material of a flange
to be used is dependent on the service duty of the line. 2eference to the piping
specification will provide such information.
0t is important to be able to accurately identity flanges as this enables
confirmation of the joint location on a '> 0?! confirmation of the piping
specification and thus the identification of the correct materials for a job.
1lan#e "tandards
+or process and utilities pipework! the two commonly used flange standards are
A1S0 $19.8 ,American 1ational Standards 0nstitute- and $S 189: ,$ritish
Standards-. A third standard! A'0 9A ,American 'etroleum 0nstitute- specifies
flanges for &ellhead and hristmas Tree 6#uipment.
+langes of different standards are not normally joined. 0f necessary to do so!
engineering advice must first be sought to ensure the comparability of the mating
flanges.
1lan#e 1acin#s
There are three types of flange facings commonly found on a plant. The surface
finish of the facings are specified in the +lange Standards note that they are
refined and superseded by $' 6ngineering )S 1<23< 3 'ipe +langes and
+ittings. A Section on surface finish on the different flange facings is in this book
extracted from )S 1<23< 3
8
(in# Tpe Joint @(TJA
Typically found on the most severe duties! for example high pressure gas
pipework. 2ing type metal gaskets must be used on this type of flange facing.
(TJs to API -A Tpe B5 B" $)-, and AN"I B$-+)(
The seal is made by metal3to3metal contact between the gasket and the flange
groove. The faces of the two opposing flanges do not come into contact and a
gap is maintained by the presence of the gasket. Such 2T* flanges will normally
have raised faces but flat faces may e#ually be used or specified.
(TJs to API -A Tpe BB>
A'0 9A Type $A flanges seal by the combined effect of gasket compression and
flange face to face contact and will therefore always have raised faces. The
flanges also use special metal ring joints. A Type $A flange joint which does not
achieve face3to3face contact will not seal and should not be put into service.
(aised 1ace @(1A
Sealing on a 2+ flange is by a flat non3metallic gasket ,or a flat metallic gasket
for special applications-! which fits within the bolts of the flange. The facing on a
2+ flange has a concentric or phonographic groove with a controlled surface
finish. 0f the grooves are too deep ,or a rough surface finish-! then high
compression is re#uired to flow the relatively soft gasket material into the
grooves. Too shallow ,exceptionally smooth surface finish- and again high
compression is re#uired as a leak path then becomes more possible. 0t is
important to always check the flange surface finish for imperfections which would
make sealing difficult. A radial groove for example is virtually impossible to seal
against.
1ote that the surface finish on the flange facing depends on the type of gasket
being used.
+urther details are given in section ,Spiral &ound )askets- and ,)raphite
gaskets-.
1lat 1ace @11A
Sealing is also by compression of a flat non3metallic gasket! ,very rarely a flat
metallic gasket-! between the phonographic7concentric grooved surfaces of the
mating ++ flanges. The gasket fits over the entire face of the flange.
++ flanges are normally used on the least arduous of duties such as low
pressure water drains and in particular when using cast iron! cunifer or bron.e
alloy! where the large gasket contact area spreads the flange loading and
reduces flange bending.
NOTE> $oth A1S0 $l 9.8 and $S 189: specify +lat +ace +langes and 2aised
+ace +langes as well as 2T* +langes. A'0 9A is specific to 2T* flanges only.
9
1lan#e 1ace (e-3achinin#
+lange +ace 2e3machining may be carried out in order to repair the sealing face
of a flange which has corroded! deteriorated or otherwise been damaged.
+lange face re3machining must be carried out by experienced personnel using
the appropriate e#uipment. A procedure for the process should be in place and
must be followed.
The extent of any re3machining must be such that the flange dimensions still
remain within the tolerance specified in the flange manufacturing standard! A1S0
$19! A'0 9A! $S 189: etc. 0ncorrect re3machining which reduces the flange
dimensions to below the minimum specified dimensions will result in possible
leakage.
1lan#e Tpes
The way in which the flange is attached to the pipe defines the flange type! as
follows(
:eld-NecC 1lan#e @:NA
The &1 +lange is butt3welded to the pipe. &1 +langes are typically used on
arduous duties such as high pressures and or ha.ardous fluids. The butt3weld
may be inspected by radiography or ultrasonics as well as 5'0 or ?'0 during
fabrication. There is therefore a high degree of confidence in the integrity of the
weld. A butt weld also has good fatigue performance and itBs presence does not
induce high local stresses in the pipework.
"ocCet :eld 1lan#e @":A
Socket weld flanges are often used on high pressure! ha.ardous duties but will
be limited to a nominal pipe si.e ,1'S- of 1.172 inches.
The pipe is fillet welded to the hub of the S& flange. 2adiography is not
practical on the fillet weld and correct fit up and welding is therefore crucial. The
fillet weld will normally be inspected by 5'0 or ?'0.
"lip on :eld 1lan#e @"OA
/sed typically on low pressure! low ha.ard services such as fire water! cooling
water! etc. The pipe is Cdouble weldedC both to the hub and the bore of the
flange and again radiography is not practical. 5'0 or ?'0 will be used to check
the integrity of the weld.
&hen specified! the S; flange will be used on pipe si.es greater than 1
1
7
2
D with
a preference for the S& flange for si.es up to and including 1
1
7
2
D
Composite 6ap Joint 1lan#e
E
omprises of a hub or Dstub end= welded to the pipe and a backing flange or
capped flange which is used to bolt the joint together. This type of flanged joint
is typically found on unifer and other high alloy pipework. An alloy hub with a
galvani.ed steel backing flange is cheaper than a complete alloy flange. The
flange has a raised face and sealing is with a flat gasket such as a A+ sheet
gasket.
"=iDel (in# 1lan#e
As with the omposite Fap *oint +lange! a hub will be butt welded to the pipe. A
swivel ring sits over the hub and allows the joint to be bolted together. Swivel
2ing +langes are normally found on subsea services where the swivel ring
facilitates flange alignment. The flange is sealed using a 2T* metal gasket.
1lan#e "peci2ication ! Identi2ication
"peci2ication
A 2lan#e is speci2ied ? the 2ollo=in# in2ormation>
Tpe and 1acin#
&hether the flange is for example D&eld 1eck!
2T*= or DSocket &eld ! 2+=.
Nominal Pipe "iEe 2e#uired for all flanges! usually in inches
1lan#e Pressure
Class
2e#uired for all flanges! e.g. class 18:! 4::!
G::! 18::! 28:: etc
"tandard A1S0 $19.8! $S 189: or A'0 9A.
3aterial
A material specification must be stated and will
be as #uoted in the piping specification.
Pipe schedule
;nly for &eld 1eck! Socket &eld! omposite
Fap *oint and Swivel 2ing flanges where the
flange bore must match that of the pipe. e.g.
schedule 1:! 4:! <:! H:! 12:! 19: etc.
1ormally! the flange specification will be hard stamped on the flange. 0n the
case of existing plant! the information may not be legible and it is then necessary
to identify the flange by visual observation and physical measurement.
8isual o?serDation 2e#uired to identify the type of flange and type
of gasket used.
H
Phsical
measurement
2e#uired to identify the nominal bore and the
class of the flange.
heck the number of studbolts! Studbolt
diameter
Studbolt 'itch ircle ?iameter ,'?-
+lange thickness.
ompare these figures with standard flange
data as found
Pipe 1lan#es - DoFs ! DonFts
?o"s
Always visually inspect the surface finish of the flange. 0t should be clean!
degreased and free of any defects! nicks or burrs. 2aised +ace and +lat +ace
flanges should also be checked for flatness with a straight edge.
heck the phonographic or concentric groove on the face of 2aised +ace
and +lat +ace flanges. Any radial defects for example will be virtually
impossible to seal against.
2T* grooves must be kept scrupulously clean! corrosion free and
undamaged.
DonFts
&hen cleaning a flange face! never use a tool which may damage the
surface finish. A soft wire brush is recommended.
?o not use unnecessary force say by tirforing or pulling! to bring flanges
which are clearly misaligned together. This may over stress adjacent
pipework and will make sealing of the flanged joint difficult and unreliable+
Instead5 report the situation+
?o not mate flanges manufactured to different standards unless specified in
an approved design.
G
16ANGE T4PE"
1:
11
1lan#e "ur2ace 1inish ! 1lan#e Distortion
To create a seal! gasket has to fill up the voids in the flange surface present
because of surface finish and any flange rotation ,or relative distortion- between
the two surfaces.
The flange surface will thus give a broad indication of which gasket materials are
likely to be suitable. +inishes of standard raised face flanges usually fall within
the range 4.2 to 12.8m but this may be expressed in micro inch or roughness
number.
"ur2ace 2inish
5icro metre m
12.8 9.4 4.2 1.9
5icro inch 8:: 28: 128 94
(ou#hness num?er @B" /,0A 11: 1G 1H 1E
"heet Gointin#
12
The recommended surface finish for the compressed fibre jointing ,above a
thickness of 1mm- is 4.2m to 12.8m 2a ,128 in 8::in. FA- these values
are also used for graphite laminate ,above a thickness of :.Hmm-
+or tongue and groove flange facings or for very thin gaskets ,:.<mm or below- a
surface finish of 1.9m to 9.4m 2a ,94 to 2:: in. FA- is possible.
Surface finishes below 1.9m are not recommended due to their negative effect
on creep resistance of the gasket.
"piral :ound GasCetin#
This type of gasket re#uires a range of surface finishes dependent upon the
application(
)eneral 3 4.2m to 8.1m 2a ,128in. to 2::in. FA-
ritical 3 4.2m 2a ,128in. FA-
Iacuum applications 3 2.:m 2a ,H:in. FA-
"olid 2lat metal
A surface finish in the order of 1.9m2a is acceptable but for more critical
conditions! a finish no more coarse than :.Hm 2a is preferred. Again for
optimum performance! the smoother the flange surface finish! the better the
performance.
3etallic rin# Goint #asCets
The angled surfaces ,typically 24- of both grooves and octagonal gaskets and
the contact faces of oval gaskets should have a surface finish no rougher than
1.9m 2a.
3achinin# o2 2lan#e 2aces
/nder no circumstances should flange seating surfaces be machined in a
manner that tool marks extend radially across the seating surface. such tool
marks are practically impossible to seal regardless of the type of gasket being
used.
Pipeline GasCets
"election o2 GasCet material
Assuming the mating flanges are in existence! the selection of the correct gasket
material involves a logical series of considerations and these are considered in
turn.
1u#itiDe Emissions
@eightened awareness with regard to @ealth and the 6nvironment is leading to
new and more stringent standard procedures and legislation. The goal is to
reduce emissions to target levels currently based on the best available
technology. These targets will inevitably become tighter in the future. Farge
companies have been aware of the issues for a number of years and will have a
major part to play in the future standards and legislation. As early as 1GG<
+ugitive 6missions had a major impact on meeting the challenge set by major
14
petrochemicals companies. Some companies set their own high standards ahead
of incumbent legislation.
+ugitive 6mission Sources ,+luid Sealing Association-
percentage
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1u#itiDe Emissions "ources
P8(C @Pressure 8essel (esearch CommitteeA
Ti#htness
Classi2ication
Classi2ication 3ass leaC rate per mm
2or #asCet diameter
6conomy T2 :.2 mg7sec.mm
Standard T2 :.::2mg7sec.mm
Tight T4 :.::::2 mg7sec.mm
Compati?ilit =ith 1luid
The gasket should obviously not be affected by fluid being sealed over the whole
range of operating conditions. The chemical resistance chart shows the
resistance of many common jointing materials to variety of chemicals. This is a
guide only and should any doubt exist! then the gasket manufacturer should be
consulted.
Temperature
The gasket selected should have reasonable life expectancy at the maximum
temperature encountered ,or the minimum temperature if for a low temperature
application-. A broad indication of the temperature pressure ratings of the
common gasket materials is shown in the figure below.
1<
)asket materials are designed to compress under load to achieve the initial seal.
@owever! to retain that seal! the gasket should be able to resist flow ,or creep- to
prevent loss of surface stress by bolt reduction. This property is very important
and is the one that most readily separates high #uality from low #uality gaskets.
/nder ambient temperature conditions! most gasket materials do not creep
significantly! but as the temperature rises beyond 1::! creep becomes a
serious consideration.
+or all applications but particularly for low temperature applications! the following
points should be observed(
The gasket should be completely dry when installed ,gaskets for such
applications should be stored in a dry atmosphere-.
The re#uired flange loading should be applied at ambient temperature.
Notes >
1. The above information is intended as a guide to the maximum possible
ratings of each class of jointing. 0t does not imply that all the gaskets within
each generic type are suitable for the temperatures and pressures shown.
2. 6ven if the material chosen is theoretically suitable for the temperature and
pressure! other factors should be considered such as available bolting! flange
facing type! shock loadings etc.
4. onsultation with gasket experts should take place at the design stage to
ensure that the gasket selected is suitable for all conditions of the
application.
Internal Pressure
18
The gasket has to be suitable for the maximum internal pressure experienced%
this is often the test pressure! which can be J2 times the flange rating at ambient
temperature.
Iacuum conditions need special considerations but as a guide(
+or coarse vacuum ,E9: torr to 1 torr-( flat rubber or compressed asbestos
fibre gaskets.
+or high vacuum ,1 torr to 1x1:
3E
torr-( rubber K:" rings or moulded rectangular
seals.
+or very high vacuum ,below 1x1:
3E
torr-( specialised seals re#uired.
"pecial Considerations
There are many factors apart from those already considered that affect the
selection of the correct gasket material and type.
ycling onditions
0f the service conditions include fre#uent thermal or pressure cycles! then the
gasket has to be resilient enough to allow for the flange movements and
strong enough to resist the mechanical loading.
8i?ration
0f the pipeline is subjected to undue vibration! then the gasket has to
withstand the mechanical effects involved.
ErosiDe 3edia
ertain media ,e.g. solids suspended in li#uids- can slowly erode gaskets
leading to a much shorter life than expected. 0n such cases! choice of gasket
material and selection of gasket dimensions are critical.
(isC o2 Contaminatin# the 1luid
Sometimes the effect of contaminating the fluid by leaching chemicals from the
gasket should be considered. Typical examples are in the sealing of potable
water! blood plasma! pharmaceutical chemicals! food! beer! etc.
Corrosion o2 1lan#es
Some flange metals are prone to stress corrosion cracking ,e.g. austenitic
stainless steel-. &hen using these! care should be given to ensure that the
gasket material does not contain an unacceptable level of leachable impurities
which may induce the corrosion. Such impurities include chloride ions.
19
Inte#rit
&hen integrity of a gasket is of prime importance ,e.g. when sealing a highly
toxic chemical-! the choice of gasket may be influenced by the re#uirement for a
larger safety margin. As an example! a spirally wound gasket with an outer
retaining ring may be selected in place of a compressed asbestos fibre gasket.
Econom
Although a gasket is a relatively low priced item! the conse#uential expense of
leakage or failure should be considered when deciding on #uality! type and
material of the gaskets.
Pipeline GasCets
orrect gasket selection and installation is of paramount importance. The gasket
creates the seal between the two flange faces and contains the internal pressure
at that joint.
(TJ @(in# Tpe JointA GasCets
2T* gaskets are forged rings that fit into the machined groove of an 2T* flange.
2T* gaskets are generally used for high pressure applications. Sealing is by
metal3to3metal contact between gasket and flange. There are three different
types of ring commonly available(
( tpe+ These are either oval or octagonal in cross3section. The oval 2T* is the
original design. The octagonal 2T* is a modification to the oval design and
provides better sealing+ ( tpe rings may be specified for class 18: to 28::
flanges though are typically found on class 18:: flanges and often class G::.
The piping specification will state whether an octagonal or an oval joint is to be
used. 2 type rings may be used on either flat face or raised face 2T* flanges.
1E
(TJ GasCet Identi2ication and "peci2ication
Tpe> &hether 2! 2A or $A. 0f 2! state whether octagonal or oval. The type
of ring to be used will be specified in the piping specification.
(in# num?er> +or example 2<9 will fit a 9 inch 1$ class 18:: 2T* flange.
3aterial> A variety of materials are available. Again check with the piping
specification for the correct material. The material grade will have an
identifying code. +or example(
D H "o2t iron "/$- H "tainless steel /$-
"tandard> 6ither A1S0 $19.2: or A'0 9A% as specified in the piping
specification.
Identi2ication> The type! ring number > material will always be marked on
the side of the ring.
Klin#er "piral :ound GasCets
5ost Spiral &ound )asket now being used are Klin#er C(I( Spiral &ound 419
st7st &indings and )raflex +iller! these gaskets have a /$- st*st inner ring and
carbon steel outer guide ring! but on some occasions the outer ring could be
st7st.
GasCet Nominal
ThicCness
(ecommended
Compressed ThicCness
4.2mm 2.4 3 2.8mm
<.8mm 4.2 3 4.<mm
9.<mm <.9 3 <.Gmm
E.2mm <.H 3 8mm
These gaskets are fitted with an internal guide ring which(3
'rovide an additional compression stop
2estricts the lateral flow of the gaskets towards the bore.
Acts as a heat and corrosion barrier protecting the gasket > flange.
$y filling the annular space between the gasket and flange it reduces
turbulent flow of the fluid or the possibility of the accumulation of solids! and
possible corrosion.
1H
1iller 3aterials Temperature 6imits
Special anadian Asbestos 88:
:

'T+6 29:
:

)raflex )raphite 88:

:

1onas ,Asbestos +ree- <9:

:

eramic H::
:

1lan#e "ur2ace 1inish 3icro 3eter

)eneral 4.238.1
ritical 4.2
Iacuum 2.:
The 'iping Specifications for each individual plant will be changed to
accommodate the new gaskets. The stores Iocab nos. will remain the same for
the e#uivalent si.e spiral wound type.
"piral :ound GasCet
"piral :ound GasCet
"piral :ound GasCets that ma ?e present in 2lan#es
Spiral wound gaskets are typically used on intermediate pressure systems and
will be found on class 4:: flanges! class 9:: and class G:: flanges.
S& gaskets are used on 2+ flanges with a smooth surface finish! as #uoted in!
Surface +inish Ialues for +lange +acings for class 18: to 28:: flanges.
Though there are many variations on the spiral wound gasket design! only that
which is the preferred design is described 3 that is the spiral wound gasket with
inner and outer rings.
"piral :ound "ection
This part of the gasket creates the seal between the flange faces. 0t is
manufactured by spirally winding a pre3formed metal strip and a filler material
around a metal mandrel. 1ormally the outside and inside diameters are
reinforced by several additional metal windings with no filler. &hen compressed!
the combined effect of the metal winding and the filler material will make the
seal. The filler material will flow into the grooves on the flange face and the
metal winding will then strengthen and support the filler against the flange face.
Inner 3etal (in#
The inner metal ring provides inner confinement to the gasket. $eing of a
specified thickness smaller than that of the uncompressed spiral windings! it acts
as a compression stop. i.e.( it prevents the windings from being over
compressed say due to over tensioning of the studbolts or thermal growth of the
pipework when in operation. The inner ring also fills the annular space between
the flange bore and the 0? of the spiral wound section and therefore minimises
turbulence of the process fluids at that location and prevents erosion of the
1G
flange faces. 1ote that the spiral windings should never be exposed to the flow
of the process fluids. The 0? of the inner ring should be flush with the bore of the
flange and this should be checked prior to bolting up.
Outer metal rin#
The outer metal ring acts as a compression stop and an anti3blowout device. 0t
also centers the gasket on the flange face. The spiral wound gasket should be
centered on the flange with the outer ring resting against the studbolts. 0f this is
not the case! the incorrect gasket has been chosen and should be changed.
1iller 3aterial
+or most applications in the petro3chemical industry! an asbestos filler was
usually specified. Asbestos is ha.ardous to health and even though trapped
within the spiral winding! S& gaskets should be handled with care. +ull
procedures are available and should be consulted. 'iping specifications now
#uote a Dnon asbestos= filler instead of asbestos. )raphite filler has now taken
over as being the preferred filler material
+or special applications! other materials are available! such as graphite and
ceramic fillers.
"piral :ound GasCet "peci2ication and Identi2ication Spiral wound gaskets
are supplied and identified as follows(
NP" and 1lan#e pressure class> A class and nominal pipe si.e must be
specified and must match that of the flange concerned. The class and si.e of
the gasket will always be stamped on the outer ring.
1lan#e tpe> Spiral wound gaskets are normally used on 2+&1 flanges. 0f
used on S; flanges! this should be stated as special gasket si.es will be
re#uired for 1'S up to 1
1
7
2
=
1iller material> A variety of materials are available. 1ormally asbestos was
used but now graphite! 'T+6! ceramic fillers! etc. are used predominantly.
The filler material will be specified in the piping specification. 0dentification is
by way of a colour code on the spiral wound section.
:indin# material> &inding material is important as it should be resistant to
the process conditions. The winding material will be specified in the piping
specification and is typically stainless steel. 0dentification is by a colour code
on the outer ring.
Inner rin#> The inner ring will normally be the same material grade as the
metal winding as it must e#ually resist the process conditions. 5aterial grade
will be specified in the piping specification.
2:
Outer rin#> 1ot such a critical parameter as the inner ring as it does not come
into contact with process fluids. 0t is normally carbon steel and again will be
specified in the piping specification
"tandard> /sually $S 44H1 or A'0 9:1.
"piral :ound GasCet Colour Code (e2+ Chart
:arnin#
There are some process applications =here #raphite is unsuita?le+ (e2er to
manu2acturers data sheets 2or details+
:indin# 3aterial Colour Code
The outer ring of the S& gasket will be coloured to identify the winding material(
The ring may be only coloured on the outer edge
CA(BON "TEE6 "I68E(
/,%"" 4E66O:
/$-"" G(EEN
/%'"" B67E
/&$ "" T7(I7OI"E
3ONE6 O(ANGE
NICKE6 &,, (ED
TITANI73 P7(P6E
A66O4 &, B6ACK
HA"TA66O4 B B(O:N
HA"TA66O4 C BEIGE
INC -,, GO6D
INCO6O4 :HITE
1iller 3aterial Colour Code
The spiral wound section of the S& gasket will be coloured to identify the filler
material( with flashes around the outer ring of the relevant colour.
NON A"BE"TO" PINK
G(APHITE G(E4
A"BE"TO" NONE
21
PT1E :HITE
CE(A3IC 6IGHT G(EEN
1ote that the above colour coding is based on A'0 9:1 and has also been
adopted by Klin#er! the main supplier of spiral wound gaskets to $'.
:hen inspectin# #asCets alread 2itted to 2lan#es it can ?e di22icult to
distin#uish ?et=een =hite #re and li#ht #reen+ En#ineers must ?e a=are
o2 this pro?lem+
"*: GasCet in its 7ncompressed "tate
"7(1ACE 1INI"H 8A67E" 1O( 16ANGE 1ACING"
22
@Amends AN"I B$-+)5 -+/+%+$,A All dimensions in mm
1lan#e
(atin#
Class
3ethod
o2
3achinin#
Depth
o2
"err
(adius
o2
Tool
Pitch
o2
"err
(J (A
min
m
maK
m
min
m
maK
m
@ (e2+ "td+ I"O %-0 A
$), L Turnin# ,+,) $+- ,+0 $&+) ), /+& $&+')
/,, -&),, L Turnin# ,+,$) ,+0 ,+/ $&+) &) /+& -+/
All Other than
Turnin#
-- -- -- $&+) &) /+& -+/
Klin#er Tan#ed P"3 GasCets
$' has formed a partnership with a gasket company! to change from Asbestos
based materials to 1on Asbestos based materials. The manufacturer of the
replacement material is DLlinger Ftd.=
'reviously the predominant gasket used in $' has been ompressed Asbestos
+ibre ,A+- this material covers a wide range of applications! but has a known
health risk.
The new gasket material which contains no asbestos has a stainless steel insert
sandwiched between two layers of )raphite. 0f not handled correctly the insert
may cut personnel. This type of gasket is known as a Btanged gasketB! the
gaskets are non3stick especially on stainless steel faces.
The Stainless reinforcement increases the tensile strength of the material! its
load bearing capacity and handling characteristics! it also improves its blow3out
resistance under cycling conditions. +or larger type gaskets two stainless inserts
may be used for greater rigidity and ease of handling
:hen handlin# this tpe o2 #asCet al=as use #loDes.
24
"erDice Temp 32::
:
to M<8:
:

3aK Pressure at $), 3pa "tress 2:: bar

(ecoDer 14 3 1GN
Compressi?ilit A"T3 1/-A 2H 3 <2N
"heet "iEe 1 x 1m or 1 x 1
.
8m
The 'iping Specifications for each individual plant will be changed to
accommodate the new gaskets. The stores Iocab nos. will remain the same for
the e#uivalent si.e ring gasket.
1lat (u??er GasCets
+lat rubber gaskets are normally found in the least ha.ardous and aggressive of
conditions such as low pressure water services. 2ubber gaskets are limited in
use by temperature! pressure and chemical resistance. They are also liable to
creep! e.g.( if subjected to excessive bolt loading or repeated hydrotest.
2ubber gaskets are usually full face and are used on flat face flanges. ;f the
variety of rubbers available! that most commonly used as a gasket is neoprene.
;ther rubber materials include natural rubber! Iiton and 1itrile.
(u??er GasCet "peci2ication and Identi2ication
1'S and flange pressure class( Always to be #uoted. 0t should be marked on
the gasket. 0f not check the correct fit of the gasket on the flange.
Alternatively the gasket may be cut from rubber sheet. The bore of the pipe
must not be restricted by the gasket and that the entire face of the flange
must be covered. heck the thickness of the gasket by reference to the
piping specification.
5aterial( &hether neoprene! nitrile! etc. 2efer to the piping specification.
2<
NNo= not in use @ In2ormation Onl A
Compressed As?estos 1i?re GasCet @CA1A
A+ gaskets were used for low pressure applications and were typically found in
class 18: and class 4:: flanges! and will probably still be in many flange
applications.
A+ gaskets were normally used on 2aised +ace flanges ,self3centering flat ring
type gasket-! but may also have been used on +lat +ace flanges ,full face type
gaskets are re#uired-.
Though of apparently simple design! the A+ gasket should be treated with
e#ual respect as with all gaskets to ensure effective sealing
A+ gaskets are manufactured from asbestos fibres bonded in a nitrile rubber
compound. Sealing is by a similar mechanism to the spiral wound gaskets
where the gasket material is soft enough to flow into the phonographic groove on
the flange face when compressed. orrect gasket thickness is therefore
important.
The surface finish on 2+ flanges used with A+ gaskets will be relatively coarse
compared to that for S& gaskets. The re#uired surface finish will be as stated in
relevant section on 18: flanges.
The gasket may or may not be coated with graphite The graphite has non3stick
properties and enables the easy removal of the gasket when a flange is split.
)raphite coated A+ gaskets S@;/F? 1;T be used in the following instances(
Austenitic stainless steel flanges on water duties.
Aggressive water duty ,e.g. cement lined pipework.-
?uties where temperatures exceed %), degrees .
2emember that A+ gaskets contain asbestos and should therefore be handled
carefully. 0f shaping a A+ gasket! do so by cutting! shearing or punching 1;T
by sawing! grinding or drilling. 0f removing an old A+ gasket from a flange! wet
the gasket with water to absorb any asbestos dust that may be freed! especially
if the flange has to be scraped clean. Foose A+ waste should be disposed of
in sealed polythene bags and labeled as containing asbestos with an Dasbestos
warning= tag. +ull procedures are available and should be consulted.
A+ )asket Specification and 0dentification
NP" ! 2lan#e pressure class> Always to be specified. The information
should also be marked on the gasket.
28
0f not! check the correct fit of the gasket on the flange. 0t should be centred
when resting on the studbolts and the bore of the pipe should not be
constricted. Alternatively the gasket may be a full face type! si.ed to the ;?
of the flange! particularly for small bore ,less than 2 inch 1$- pipework.
heck the thickness of the gasket. 0t will be #uoted in the piping
specification.
GasCet coatin#> i.e.( whether graphited or non3graphited. The piping
specification should be consulted.
"tandard> 1ormally $S 1H42 or $S 2H18 will be specified.
GasCets - DoFs ! DonFts
DoFs
heck the type! class! si.e and material specification of
the gasket before using it. heck with the piping
specification to confirm that it is correct.
heck the gasket for damage! nicks! etc. 6nsure that it is
clean and free from any contaminants before use.
6nsure that the gasket fits correctly.
heck the flange face to face separation once the gasket
has been installed and the bolts tensioned. A uniform
separation is re#uired. 0f not! the gasket could be locally
crushed or deformed and will not seal properly.
&ire brush studs7bolts and nuts to remove any dirt on the
threads. 6nsure that the nuts can run freely down the
threads before use. oat the studs7bolts with a thin film of
an approved lubricant prior to installation.
DonFts
?o not re3use old gaskets. +or every joint being made up!
a new gasket should be used.
?o not use a gasket that has no identification. 0t may
appear to fit the flange but this is not a guarantee.
29
?o not cut or deform a gasket to fit a flange. 0f the gasket
doesn"t fit! the wrong one has been chosen.
GasCets 1or 6ined Pipe=orC
*oints in lined pipework are invariably flanged and gaskets often need to create
a seal despite many of the linings being of a soft nature. orrect gasket
selection is particularly important since (
many linings whilst having a smooth finish! have undulating surfaces on the
flanges due to the method manufacture ,e.g. glass-!
there is usually a good reason for using lined pipework ,e.g. chemically
aggressive fluid or pharmaceutical fluid- and the gasket often has to be e#ual
to the lining in terms of chemical resistance and freedom from contamination!
linings tend to be of a fragile nature and bolt loads have to be kept low to
prevent damage. This limits the choice of gasket material!
the gasket material has often to withstand the effects of aggressive cleaning
fluids as well as the service fluids.
Tpes o2 linin#s aDaila?le
(u??er lined
A soft rubber gasket can be applied! a steel or ebonite spacer can be used to
prevent over compression.
Plastic lined
)askets are not normally re#uired but there are exceptions(
&here there are dissimilar flange connections ,e.g. pipe to valve-
&here the lining is too undulating.
&here the lining is applied via a dripping process! e.g. 'I
6ead lined
reep resistant 'T+6 or a 'T+6 envelope with soft rubber insert can be
used.
2E
Glass lined
'T+6
Compact 1lan#ed Joints
A variety of different joint designs fall under the category of compact flanges.
6ach design is uni#ue to its manufacturer and subse#uently reference to the
joint normally involves #uoting the manufacturer"s name or a trade name. +or
example )raylok! ?estec! Taper3lok and so on.
ompact flanges are used where savings in weight! space or material cost
,especially so with exotic materials- are an advantage.
0t is important to be able to recognise the different types of compact flanges
available and brief descriptions of some available types follow(
Taper-6oC
The Taper3lok flange employs a conical gasket which is wedged as the joint is
tightened! thereby sealing on both its inside and outside surfaces. As internal
pressure increases! the tapered gasket is forced in between the mating flanges
thereby further tightening the seal. $ecause of the male7female configuration
re#uiring more parts! Taper3lok joints have not been widely used by $'.
The gasket 3 or joint ring is externally visible allowing confirmation of installation.
A relatively wide flange separation is re#uired to remove the sealing ring and this
may cause problems especially where springing of pipework is difficult.
Taper3lok flanges have been shown to be sensitive to misalignment. The flange
gap must be maintained within :.4mm uniformity in order to prevent leakage.
Sealing ring alignment must also be carefully observed during bolt tightening.
;vertightening of the bolts can result in damage to the seal ring and careful
control of the bolt lubrication and tor#ue"s is therefore essential.
2H
@ "eal (in# is sho=n loose and not sealed A
GralocC Couplin#
The )raylock oupling comprises bolting! clamps! hubs and a seal ring as
shown below. The function of the bolts is primarily to draw the two halves of the
clamp together and not to resist internal pressure. The seal ring is
self3energised and also pressure3energised.
&hen assembling a joint! before bolting up! the stand3off between the seal rib
and the hub should be checked with a feeler gauge. 0f the stand3off is smaller
than the manufacturerBs recommendation! the seal must be replaced.
The seal ring and the hub sealing faces must always be lubricated before
assembly. A thin coat of molybdenum disulphide is normally recommended
2G
;ther manufacturers produce compact flanges which are virtually identical to the
)rayloc. +or example ?estec! Seaboard Floyd! Techloc! Spolok! etc. 1;16 ;+
T@6S6 ?6S0)1S A26 01T62@A1)6A$F6.
Other Desi#ns>
4:
There are number of other compact flange designs! some of which are either no
longer manufactured or for which the manufacturers have ceased to exist. The
following diagrams illustrate a few such designs.
41
Compact 1lan#es "peci2ication ! Identi2ication
1'S and flange pressure class( Some compact flanges use A1S0 $19.8
pressure ratings such as class 9::! G::! 18:: etc. ;thers re#uire a design
pressure to be specified.
'ipe schedule( As specified in the pipe specification.
5aterial( 2efer to the piping specification which will detail the material grade
of the different components of the compact flange. Also obtain the
manufacturerBs product data which will interpret any abbreviations for material
grade that may be stamped on the components.
5anufacturerBs name7Trade name75odel number( A model number may also
be re#uired for a particular compact flange design. heck with the
manufacturerBs product data. This is then sufficient to specify all the different
components of the compact flange( the seal ring! clamps! hubs! even the
studbolts. The components will all be uni#ue to the one manufacturer.
Compact 1lan#es - DoFs and DonFts
42
DoFs
+ollow the manufacturerBs installation procedures. 6ach procedure will be
different so it is important to use the correct one.
&hen assembling compact flanges that consist of two clamps! such as!
)rayloc! always align the clamps such that they sit to the left and to the right
of the pipe as opposed to top and bottom. This prevents water from collecting
in the clamps.
5any manufacturerBs state that their gaskets may be re3used. Always inspect
a gasket for damage! deformation and wear before re3using it
+ollow the manufacturerBs disassembly procedures. ompact flange designs
which include hubs! clamps and pressure energised sea rings such as
)rayloc and Seaboard Floyd lamplok should be disassembled with care.
Such designs can continue to contain residual pressure even with the
studbolts removed! due to the wedging action of the clamp halves.
Al=as slacCen the compact 2lan#e ?oltin# and phsicall dislod#e the
clamp halDes as a sa2e#uard a#ainst an trapped residual pressure+ Onl
then should ?oltin# ?e 2ull remoDed and the 2lan#e disassem?led+
DonMts
1ever mix and attempt to match parts of different compact flanges. They may
look the same but none are interchangeable. ;nly use the parts from the
specified flange manufacturer.
BreaCin# Joints
$efore starting! check that your permit to work is valid for the job in hand! and
that the right protective clothing7e#uipment is worn.
onfirm that the line has been drained vented or isolated as appropriate
before attempting to break a joint.
6nsure that the correct tools for the job are available and are used.
&hen attempting to break a joint! avoid standing directly alongside or
underneath the joint. Always break the bolt that is furthest away from you first!
preferably the bottom furthest bolt.
ontinually check for leakage! seepage or signs of pressure in the line 3 a
hissing sound! a smell of gas etc. /se a pair of wedges away from you to
determine this.
I2 at an sta#e there is a si#n o2 pressure in the line5 stop =orC
immediatel+ (e-ti#hten the Goint to contain the leaC and then report the
situation to our superDisor+ The line isolation =ill haDe to ?e checCed+
1ever remove nuts from the studs until you have ascertained that the
pipework is empty.
44
0f a blank or a spade is being removed! or a spectacle blind is being swung!
check the weight from the tables. 0f necessary! support with a chain block
before any work continues. 6nsure the spectacle is clean and free from rust
before releasing the studbolts.
$efore finally parting a joint! always assess the forces on the pipe. &ill the
pipework spring apartO 0s one half of the joint unsupportedO Temporary
supports may be needed.
3aCin# Joints
$efore starting! check that your permit to work is valid for the job in hand! and
that the right protective clothing 7 e#uipment is worn.
heck if there is a procedure in place for carrying out the intended work 3 and
if so follow the procedure.
?etermine the type! si.e and class of the flange to be bolted. ?etermine the
piping specification number of the pipework. heck the material! coating and
si.e of the studbolts. heck the type! pressure rating and si.e of the gasket.
The studbolts and gasket specifications for the flanged joint must always
match the descriptions in the piping specification document.
;nly use the correct materials for the job. NeDer use dama#ed materials !
al=as use a ne= #asCet =hen maCin# up a Goints+
0f using a Kcut from sheet" gasket! ensure that the bolt holes and edges are
flat with no burrs or ridges as these will result in uneven stress loading and
may cause a leak
6nsure that the correct tools for the job are available and are used.
6nsure the joint faces are clean before inserting joint.
Iisually check the flanges for e#ual gap. 0f a larger gap appears on one side
of the flange tighten the bolt which corresponds with the larger gap first.
6nsure the flanges are parallel after tightening.
Attach any PA Tags to the flange when applicable
Boltin# 1or 1lan#es ! CoDers
Boltin#
0t is important to always use the correct nuts and bolts or studbolts in a given
location and as defined in the piping specification.
Bolt 3aterial Grade
hoice of material grade is dependent on the duty of the line. /sing incorrect
bolting could have serious conse#uences. +or example! normal alloy steel
bolting ,$E- on a low temperature service is not suitable as the bolting will be
susceptible to brittle fracture. Stainless steel bolting has limitations at high
pressure due to the relatively low strength of the stainless steel.
The piping specification will always specify the correct material grade of bolting
to be used on a flanged joint. ommon bolt specifications are abbreviated as
follows(
1ormal alloy steel( grade $E bolts x grade 2@ nuts.
Fow temp. alloy steel( grade FE bolts x grade F< nuts.
4<
Austenitic stainless steel( grade $H5 bolts x grade H5 nuts.
0f cutting bolts always cut the end which is not stamped see drg. $elow
Bolt Thread
The thread on all studbolts used on flanged piping joints is a /nified 0nch Series
to either $S 18H: or A1S0 $l.1. The thread is specified by #uoting a certain
number of threads per inch.
+or alloy steel and stainless steel bolting two thread types are used(
$olt diameters up to and including 1 inch 3 a unified coarse ,/1- thread is
used. The number of threads per inch depends on the diameter of the bolt.
$olt diameters 1.17H= inch and above 3 H threads per inch ,T'0- or the H /1
series is used.
All studbolts that are supplied to site should always conform to spec.
Bolt Coatin#*Platin#
$olting may be purchased with a variety of different coatings. The coatings are
designed to facilitate bolt tensioning and to protect the bolt material from
corrosion. Typical bolt coatings and plating include .inc plating! cadmium plating
and 'T+6 coating.
$olting may be lubricated with compounds such as BE6JONA 0&$$ H+ P+ ANTI-
"IEJE5 a nickel based lubricant should be used on stainless steel flanges to
prevent galling of the metal surfaces as the bolts are tightened.
1ote that bolts with different coatings re#uire different tor#ue values to achieve
the same bolt tension. +or example! a dry! rusty studbolts re#uires substantially
more tor#ueing than a 'T+6 coated studbolt. 0t is therefore important not to mix
studbolts with different coatings on a given flange! as it will be difficult to achieve
a uniform bolt tension on all the studbolts. +ull procedures are available on bolt
tightening and should be consulted.
A Note o2 :arnin#> admium plated components give off toxic fumes when
heated to sufficiently high temperatures. Therefore heat should not be applied to
release tight bolts. +urthermore! gloves should be worn when handling cadmium
plated components to prevent skin abrasions.
$olt Specification and 0dentification
Bolt diameter> A flange of given class and si.e will have a specific bolt hole
diameter and a bolt diameter to suit.
Bolt len#th> This is specific to the flange type! class and si.e. Two
exceptions to the standard bolt length are(
48
0f the flanges are to be tightened using bolt tensioning e#uipment! the bolt
length must be long enough to suit the e#uipment.
+or flanges separated by a spade or spacer consider the spade thickness
and the additional gasket for selection of the studbolt length.
3aterial #rade> As specified in the piping specification.
The studbolt material grade will be stamped on the end of the studbolt! either
$E! FE etc.
The nut material grade will be stamped on the end of the nut% e.g. 2@! F< etc.
Bolt coatin#> As specified in the piping specification. i.e.( cadmium plating!
.inc plating! 'T+6 coated! etc.
Thread> Should be the /nified 0nch Series as specified in the previous
section.
Nuts> Should be Dheavy series= hexagon nuts.
"tandard> +ull bolt material specifications are given in section further
sections
Tension Controlled 1asteners - (ota?olt
The only practical direct stress7strain measurement techni#ue currently available
uses a specially adapted bolt such as K2otabolt". See drawing below.
These bolts can be utilised with any tightening techni#ue to achieve the load! but
the key is that the load ,strain- is being measured directly to give an indication of
bolt tightness.
The bolt consists of a standard industry bolt which is drilled at one end along the
axis to accept a headed pin and cap mechanism which acts as a mechanical
strain gauge.
The drawing shows the arrangement( the headed pin is positively anchored to
the base of the hole and retains a rotor and cap which is free to spin in a pre3set
air gap between the rotor and bolt face.
49
&hen tightening takes place the stud begins to stretch ,proportional to load- but
the head pin does not! thus the air gap closes as tightening continues to extend
the bolt. &hen the air gap is fully closed the rotor locks. The pre3set air gap is
directly proportional to the bolt extension ,strain- and hence the stress in the bolt
,and load transferred to the gasket joint-. The user simpl turns the cap ?
2in#er and thum? =hile ti#htenin# the ?olt until the cap locCs+ ontinued
tightening is unnecessary and simply over3compresses the gasket and operates
the bolt nearer to its yield point. ;ver extension of the bolt does not damage the
strain gauge mechanism since the now locked rotor transfers load to the pin
which then starts to extend with the bolt. &hen the load is removed the pin
returns to its original length along with the bolt ,unless it has been overstressed
beyond yield-.
6very 2otabolt is individually loaded in the factory in order to pre3set the air gap
for the re#uired load. The set load is then stamped on the end of the cap for easy
identification.
2otabolts are! however! much more expensive than standard bolting and should
only be used where service duty is severe or previous history of joint leakage
justifies. +or example! the cost of continually +urmaniting a troublesome joint!
together with the possible hydrocarbon losses and even unscheduled plant
shutdowns may easily justify the added expense. 2otabolts have already been
used throughout $' on troublesome heat exchangers > flanges.
+or such troublesome joints or new exchanger designs a standard data sheet is
available to allow engineers to collect all the essential details for a joint design
check to be made.
Comparison o2 techniNues
4E
The table below gives a guide to the accuracy of achieving the target bolt load (
TechniNues>
0mpact &renches Q9:N
@and Spanners Q9:N
5anual Tor#ue &renches Q4:N
Tor#ue 5ultipliers Q4:N
'neumatic Tor#ue 5ultipliers Q<:N
@ydraulic Tor#ue &renches Q4:N
@ydraulic $olt Tensioners Q1:N
2otabolt Q 8N
BP OIL & CHEMICALS
GASKET/BOLTING DESIGN DATA SHEET
Dimensions to:- BS 5500: 1!
ASME "III A##en$i% & - ANSI B1'(5
)De*ete +s +##,o#,i+te-
General Notes 2or (ota?olt suppl and installation>
1 $olt grade is stamped on opposite end of bolt to
2otabolt cap.
& 0f bolt tensioning is to be used for the tightening
mechanism ! then the extra length! length will be
supplied at the opposite end to the 2otabolt cap. &hen
bolt tensioning the 2otabolt cap must be at the
opposite end to the extra length.
. ;n large flanges! to obtain uniform and BlockedB
2otabolts re#uires several trips around the bolt circle
when the unit is cold.
As the temperature rises! you can expect to flog the bolts a
further 23< times to obtain the re#uired tension settings. 0t
is important that your detail plans reflect this significant
man3hour content correctly.
I$enti/i0+tion 1,om D,2 inse,t - S3et04 o, +tt+04ments
4H
&01 1o
TA) 1o and /nit
*oint 0dentification
;riginal design code
Rear of 5anufacture
5anufacturer
Desi2n $+t+ 5e6( /o, 0+*0( /o, 7o*tin2 / 8oint 1*+n2e +n$ Bo*t In/o,m+tion
"hell "ide Tu?e-"ide Dimension On
Dr#+
Dim Bolt Data
?esign
'ressure
+lange OD A
1o of $olts
?esign
Temperature
+lange OD B ?iameter of
$olts
;perating
'ressure
$olt PCD C
"pecial Boltin# 4E" *NO
orrosion
Allowance
+ace to +ace @"ite
ChecCA
B 2otabolt
2e#uired
Res 1o
?uty +luid +lange Thickness ,not
including raised face-
t
$olt 7Tension
re#.
Res 1o
;riginal Test
'ressure
2aised face r2 S /nless re#uested otherwise! all
2otabolts will be supplied with
Comment
s
@ub length h extra length of 2
1
72 3 4 threads at each
end over dimension A and two
standard nuts.
@ub Thickness!
+lange 6nd
#$ ;r @ub ;?
flange end
@ub Thickness
Shell 6nd
#, @ub ;? shell
6nd
+lange face
surface finish
Smooth +ace
4.23 9.4um
Spiral +inish
9.87 12.8um
Spiral +inish
12.87 28um
Special *oint onfiguration i.e. tongue
and groove 3 detail re#uired
Res ,drg attached- 1o
M+te,i+* G,+$es
1lan#e "hell Boltin#
E%istin2 G+s3et D+t+
5aterial Thickness @t$A ;? ,Go- 07? ,Gi-
Type
2e#uester2e#
uestor
Asset ?ate
'hone7+ax 1o
Hdraulic Bolt Tensionin#
@igh pressure flanges! large diameter flanges and flanges on ha.ardous
services are often made3up using @ydraulic $olt Tensioners.
The $olt Tensioners operate by hydraulically Dstretching= the studbolt to a pre3
defined limit after which the operator is then able to hand3tighten the nuts. The
hydraulic load is then released and the studbolt remains tensioned. The
advantage of tensioning ,stretching- against tor#ueing is that the process is not
dependent on the type of lubrication used and eliminates the effect of friction
under the nut and between threads. Accurate bolt tensions are therefore
obtained.
To pull down the flange evenly! several bolts can be tensioned at the same time.
All the studbolts will eventually be tensioned after successive Dpasses= of the bolt
tensioning e#uipment.
1ote that the use of the bolt tensioning e#uipment usually re#uires the studbolts
to protrude past the nut by an additional bolt diameter. ;bstructions such as
pipe supports and instrument tappings may prevent the bolt tensioning
4G
e#uipment from being fitted over the studbolt. 0n such cases! hydraulic tor#ue
wrenches will then be used to tension the bolts.
@ydraulic $olt Tensioning is a specialised activity. ;nly trained personnel carry
out the bolt tensioning using e#uipment in good order.
+lange and $olt 'rotection
onsiderable time may be lost when attempting to loosen rusty studbolts.
Therefore to protect the studbolts from deterioration! particularly those in an
exposed environment! flange protectors and bolt ,or thread- protectors are used.
+lange protectors fit around the circumference of the two mating flanges and the
enclosed space is then filled with a grease. Thread protectors fit over the nut
and are also filled with a grease via a grease nipple. Alternatively! grease
impregnated fabric such as D?ensotape= may be used to protect studbolts.
+lange and thread protectors are most typically found on flanges which have
been hydraulically bolt tensioned.
Boltin# - DoFs ! DonFts
DoFs5
6nsure that the correct si.e and material of bolting is used. ,2efer to the
piping specification-.
Allow for two threads to be exposed outside the nut once tightened% this is
good practice. The only exception is when a flange re#uires hydraulic bolt
tensioning and the additional length of bolt to be exposed outside the nut will
be specified.
;nly use clean! rust free nuts and studbolts.
oat the stud! the nut thread! the nut and the flange bearing surfaces with the
selected bolt thread lubricant.
<:
DonFts
?o not use damaged or worn studbolts! bolts or nuts.
?o not use nuts or bolts that do not fit correctly together.
?o not use bolting that can not be correctly identified.
?o not mix studbolts with different coatings on a particular flange. ?ifferent
bolt coatings re#uire different tor#ue"s to achieve the same bolt tension! as
some coatings are more lubricating than others.
1uts should not be assembled with the hard stamp or pad against the flange.
The machined face should always come into contact with the flange.
?o not use bolting which is not clearly marked with the correct material grade
3 a wrong assumption could have serious conse#uences.
3anual Bolt Ti#htenin#
;nce a flanged joint has been prepared! the correct gasket obtained and the
studbolts cleaned! the joint may be assembled. +or successful jointing of a
flange! it is important to evenly tension the studbolts. /neven bolt tensions or
incorrect bolt tensions will not seat the gasket properly and the end result will be
a flange that is likely to leak when under test or in service.
0f using a tor#ue wrench to tighten studbolts! a bolt tightening procedure should
first be obtained in order to determine the correct tor#ue settings. The tor#ue
re#uired to achieve a given bolt tension will be affected by the following factors(
1ominal bolt diameter.
$olt material grade.
$olt lubrication.
0f using a tor#ue wrench! ensure that it is accurately calibrated.
<1
arefully fit gasket into position taking care not to damage the gasket
surface. 0nstall bolts7studs hand tight in turn.
Tor#ue to a maximum of /,O of the final tor#ue in an acceptable se#uence.
Tor#ue to -,O of the final tor#ue value using the same tightening se#uence.
Tor#ue to the final tor#ue value using the same tightening se#uence.
ontinue with one final pass! tor#uing the bolts7studs in a clockwise
se#uence.
0f the bolts7studs are large ,say above 2:mm- and the joint is subject to
extreme operating conditions! then the use of hydraulic stud tensioning
e#uipment or pre3load control system ,e.g. 2otabolt- is recommended.
2e3tighten bolts7studs to the correct tor#ue value after 2< hours in service or
one complete process cycle 3 whichever is the sooner.
(ecommended Boltin# TorNueFs
1or B'A ! B' Bolts
Nominal
Thread
Diameter
No o2
Threads
per ins
"tress
Area P
per
sN+ in+
Bolt "tress
/,5,,,P
sN+ in+
Bolt "tress
%)5,,,P
sN+ in+
Bolt "tress
-,5,,,P
sN+ in+
ins
per ins sN+ in+
TorNue TorNue
1t - 6?s Nm
TorNue TorNue
1t - 6?s Nm
TorNue TorNue
1t - 6?s Nm
Q;
2: :.:41E < 8 9 H H 11
)
*
$-
;
1H :.:822 H 11 12 19 19 22
/
*
0
;
19 :.:EE4 12 19 1H 2< 2< 42
'
*
$-
;
1< :.1:9: 2: 2E 4: <1 <: 8<
R;
14 :.1<19 4: <1 <8 91 9: H1
.
*
$-
;
12 :.1H19 <8 91 9H G2 G: 122
)
*
0
S
11 :.2289 9: H1 G: 122 12: 194
T;
1: :.44<: 1:: 148 18: 2:4 2:: 2E1
<2
'
*
0
;
G :.<912 19: 21E 2<: 428 42: <4<
$
H :.9:81 288 442 49H <GG <G: 998
$
$
*
0
;
H :.EHG9 488 <H2 844 E24 E1: G94
$
$
*
%
;
H :.GGH8 8:: 9EH E8: 1:1E 1::: 148E
$
/
*
0
;
H 1.241G 9H: G22 1:2: 14H< 149: 1H<9
$R;
H 1.<HGG H:: 1:H8 12:: 192H 19:: 21E1
$
)
*
0
;
H 1.EE24 11:: 1<G2 198: 224G 22:: 2GH8
$
/
*
%
;
H 2.:EG2 18:: 2:48 228: 4:84 4::: <:E1
$
'
*
0
;
H 2.<1:E 2::: 2E1< 4::: <:E1 <::: 8<2H
& H 2.E998 2::: 2GH8 44:: <<EH <<:: 8GE1
&
$
*
%
;
H 4.881G 41H: <419 <EE: 9<E4 949: H941
&R;
H <.<482 <<:: 8GE1 99:: HG8E HH:: 11G<2
&
/
*
%
;
H 8.<19< 8G2: H:4< HHH: 12:81 11H<: 19:9H
/; H 9.<G8E EE2: 1:<EE 118H: 18E18 18<<: 2:G8<
Bolt Ti#htenin# - DoFs ! DonFts
DoFs
+ull bolt tightening procedures are available. heck whether there is a
re#uirement to use them on the flanged joint being assembled. 6nsure that
the correct tools are available.
1umber the studs and the nuts as an aid to identification and for applying the
criss3cross bolt tightening se#uence depicted in the following figure.
0f using a tor#ue wrench! hand tighten the studbolts with a short wrench first
before tor#uing. /se the criss3cross bolt tightening se#uence.
&hen using a tor#ue wrench! consult a bolt tightening procedure to
determine the correct tor#ue settings. The tor#ue settings should be
gradually incremented for each round of tightening until the total tor#ue load
is reached. The criss3cross bolt tightening se#uence should be used for each
round.
DonFts
<4
?o not draw the flange up tight on one or two bolts only. This will cause local
gasket crushing or pinching and will ultimately result in a leaking flange.
?o not overtighten bolts and take particular care with small bolts! i.e.( those
less than 1 inch in diameter.

Hot Boltin# and Odd Boltin#
These are two techni#ues often used in preparation for maintenance work. They
must only be carried out under permit! and under controlled conditions. $ecause
they involve working on live e#uipment! each application must be specially
reviewed beforehand. ?etailed procedures must be in place for the control of
hot and odd bolting and must be observed.
Hot Boltin#
This is the se#uential removal of each flange stud?olt in turn! which is cleaned!
inspected! lubricated and then refitted or replaced. @ot bolting may be carried
out at operating pressure! though this should be reduced to the minimum
practicable. The aim is to minimise time spent freeing studs!
e.g.( in order to swing spades at say the start of a shutdown.
Odd Boltin#
This is the removal of alternate studs! so that the flange is left with onl hal2 the
normal num?er+ 0t is done whilst shutting down! once the pipe3work is close to
atmospheric pressure! but before the joint is re#uired to be disassembled.
Again! the aim is to save time when the joint is to be split.
(estrictions on Hot and Odd Boltin#
$oth these techni#ues carry the risk of leakage due to reduced gasket
compression. This is increased if there are significant piping forces. Typically!
<<
limitations on hot and odd bolting ,as would be defined in the detailed
procedures- are as follows(
1lan#es =ith less than 0 ?olts+
Joints in lines carrin# toKic 2luids+
Compact connectors @e+#+> G(A46OC A
Non standard 2lan#es+
1lan#es =ith insulatin# @or other specialA #asCets+
Joints in pipelines or risers+
Joints at ?ello=s units+

To repeat - it is essential that each application is reDie=ed ?e2orehand+ The

operation must ?e carried out under strictl controlled conditions+P
Insulation Kits 1or Bolts
0nsulation kits are designed to prevent galvanic corrosion between flanges of
dissimilar metals. +or example! a carbon steel flange bolted to a stainless steel
flange. A conducting li#uid such as water must be present between the two
flanges for galvanic corrosion to occur. ;n oil and dry gas duties! insulating
gaskets A26 1;T re#uired.
$ecause of the general unreliability of insulating gaskets! their use should be
minimised to areas where only absolutely necessary and only then! when agreed
with by your 6ngineering ?epartment.
0f used! the insulation kit will consist of the following(
0nsulating gasket.
0nsulating sleeves to be placed around the studbolts.
0nsulating washers and steel washers.
Note> The conditions that cause galvanic corrosion! ,two dissimilar metals
brought into contact with a conducting medium-! must be guarded against.
/ncoated carbon steel studbolts used on stainless steel flanges in a wet
<8
environment! carbon steel pipework screwed into brass gate valves on water
duties are two examples of Dgalvanic cells= which can easily be avoided.
Three tpes o2 Cits are aDaila?le>
+ull face gasket insulating set.
This set is suitable for both flat face and raised face flanges. The gasket style
has the advantage of minimising the ingress of foreign matter between the
flanges and therefore reduces the risk of a conductive path between the two
flanges.
0nside bolt location gasket insulating set.
0s only suitable for raised face flanges and the gasket is located within the
bolts.
2ing joint gasket insulating set.
The insulating oval 2T* will fit into a standard 2T* flange ring groove. The
kits are not used on $'A sites as they are presently considered to be too
unreliable.
Insulatin# Kit Identi2ication and "peci2ication
Nominal pipe siEe ! pipe schedule+ 5ust always be specified. 0nsulating
gaskets! unlike A+ gaskets are an exact fit! from the ;? to the 0? of the
flange.
1lan#e pressure class> Always to be specified.
"tle o2 insulatin# Cit> +ull face or inside bolt location. 2T* gasket
insulating sets are not used by $'A.
GasCet material> /sually phenolic laminate or neoprene faced phenolic
laminate.
Insulatin# Kits - DoFs ! DonFts
DoFs
Always use a new insulating kit which has not been removed from the
manufacturer"s sealed package. )ood insulation re#uires the insulating parts
of the kit to be clean and undamaged.
+ollow the manufacturer"s installation instructions.
/se a tor#ue wrench or tensioning e#uipment to tension the studbolts to the
manufacturer"s recommendations. This is important as insulating gaskets are
particularly susceptible to splitting or crushing if overloaded.
6nsure that the flange face and the studbolts are clean.
heck for any conducting paths between the two mating flanges which would
otherwise render the insulating gaskets ineffective.
<9
0f in doubt! seek advice from your 6ngineering ?epartment.
DonFts
?o not re3use old! damaged or unclean insulating kits. These will not provide
effective insulation and may be subject to gasket failure.
?o not mix and match parts from different insulation kits.
?o not use air driven impact tools when bolting up a flange as they may
cause the insulating washers to crack.
"padin# And BlanCin# O2 1lan#es
A line is positively isolated by either inserting a spade between two flanges!
swinging a spectacle7blind or installing a blind flange on the end of a flange.
/se of the correct spades or blind is imperative as the thickness of the spade is
calculated to withstand the full test pressure of the line being isolated. 0f too thin
the spade may bow between the flanges or even failTT
See a selection list of reversible spades thicknesses for the different flange si.e
and classes.
$efore inserting or swinging a spade! the line must be depressurised and gas
freed. heck the face of the spade or spectacle for pitting as this face may have
been out in the weather for a considerable period of time The same safety
precautions as when breaking any flanged joint apply here.
<E
&hen inserting a spade or spectacle blind! always use new gaskets and use the
same procedure for bolting up a flange of e#uivalent si.e and class.
0t is important recognise the status of a spade as this indicates whether the line
has been isolated or not. The following diagrams illustrate the basic difference.
"cre=ed Pipin# Joints
"cre=ed Pipin# Joints
The use of screwed piping joints especially on new installations or plants is
becoming increasingly uncommon. ;n older sites! an abundance of screwed
joints may still be found on a variety of services.
Threaded Joints
A variety of threaded joints exist. Those used on pipework are always tapered
and identified by a standard! either 1'T ,American 1ational Taper 'ipe Thread-
or $S' ,$ritish Standard 'ipe Taper Thread-. The two threads are not
interchan#ea?le+ $oth U= > V= nb $S' > A'0 have the same number of threads
,T'0- but have differing thread angles.
Sealing on a threaded joint will only take place on 2 to 4 threads within the joint
once fully tightened. A thread compound is used to lubricate the threaded joint
when initially making it up. As the joint is tightened! the compound is forced into
the peaks and troughs of the thread thereby blocking potential spiral leak paths.
Sealing between the mating sides of the thread is primarily by metal3to3metal
contact% the thread compound will assist this by filling any surface imperfections
such as scratches on the thread faces.
<H
"ealin# on a threaded Goints
(e2erence Documents
$' 2' <231 ,formerly '12-
$';)20F 'iping Specification 657STA17<23:1
$';)2F 'ractice 3 /se of Threaded +ittings 657':/<23:2
$S 9G2: 't 1 Suitability of non3metallic products on potable water duties
Aim
*ointing compound is to act as a lubricant and sealant to provide a pressure tight
joint. 1o compound or tape to be used if the fittings are to be welded
<G
0t shall be stable and not react unfavourably with either the service fluid or the
piping material and shall not be subject to any disintegration that could lead to
line blockages. The system should also have an earth continuity.
"ealin# on a threaded Goint is assisted ?>
PT1E Tape
'T+6 tape is the most common Dthread compound= available. The correct
amount of 'T+6 tape used on a threaded joint is very important. Too little! and a
seal is unlikely to be made. Too much could ?e lethal+ PT1E tape must neDer
?e used to ?uild up a thread - =hen under pressure the Goint could ?lo=
apart+
'T+6 is not to be used on bull plugs on heat exchangers. Fi#uid thread
compound only is to be used as there is no isolation between the thread and the
process.
'T+6 tape is supplied in several thicknesses ranging from Standard ,:.:E8mm
thick- to @eavy ?uty ,:.2mm thick-. &hich to use depends on the pipe ,or
tubing- si.e and the maximum pressure. @eavy ?uty tape is used on
Dmechanical= pipe joints. Standard tape is commonly used on low pressure ,up
to 1: bar- small bore ,4 to 28mm diameter- instrument tubing.
6iNuid Thread Compounds
A variety of li#uid thread compounds are available that will lubricate and seal a
threaded joint. There is no risk in the Dover3application= of a li#uid compound! as
there is with 'T+6 tape. 6xcess li#uid will simply exude from the joint.
The manufacturer"s recommendations on use must always be followed. Some
compounds have limitations on service duties. ;thers re#uire a setting time
before pressure can be applied to the system. Fists of the variety of thread
jointing compounds and their limitations on use are listed on the next page.
*ointing compounds should not be applied to any threaded joints on S7t Steel or
other exotic materials until the chemical compatibility has been checked.below(
Ta?le o2 Thread Jointin# Compounds
Thread "erDices
"ealant
"erDice Thread
"iEe
Temp
@
o
C A
Pressure
(an#e @
?ar #A
PT1E Tape
,To $S82G2! Standard!
:.:E8mm-
All services! except( 3
?ownstream of 0nstrument Air
+ilter7 2egulators.
3Air to $reathing Apparatus
/p
to
1= nb
31G:
to
M2::
/p
to
1:
PT1E Tape
@To $S82G2! @eavy
?uty! :.2mm-
All services! except(
3?ownstream of
0nstrument Air +ilter 2egulators.
/p
to
1.8= nb
33 1G:

to
/p
to
1::
8:
3Air to $reathing Apparatus

M2::
Perma?ond A$/$
,Anaerobic
Adhesive7Sealant-
All services! except( 3
2efrigerant 222
3Fow Temperature yclic duties
with differing metals.
/p
to
1.8= nb
3 3 88

to
M 18:
/p
to
2:E
(ocol MOilsealM
,Thixotropic li#uid-
All services! except((3
3Sodium @ypochlorite
3 5ethanol
3 2efrigerant 222
3 +irefighting hemicals
3hemical 0njection +luids
/p
to
1.8= nb
3 3 8:

to
M2::
/p
to
14H
(ocol M1oliac
5anganese
Applications ,with 'AB
,Finseed ;il Slight ;il
$ased 'aste-
@igh 'ressure &ater
Applications with slight oil
ontamination-
1ot Suitable for ;il Service
/p to
1.8= nb
9:: 5ax 2:: 5ax
:ater
Porta?le
:ater
Non-
Porta?l
e
$,,
psi#
"team
Air Hdroca-
r?ons
H1
Acid
Brine
Boss :hite

Boss Green

Boss Graphite

Boss 3a#nesia

"ta# A

"ta# B U

PT1E+ Paste Gold End

Capaltite

U "ta# B is recommended 2or use in corroded or poorl machined threads5 ?ut
onl =hen the pre2era?le alternatiDe o2 a correctl made5 #ood condition Goint
is not 2easi?le+
"cre=ed 7nions
&hen pipe rotation is not permissible or practicable! say when joining a screwed
pipe system! a screwed union is used. A threaded ring nut connects the two
halves of the union and the seal is made by metal to metal contact of the profiled
faces shown below. The two halves of the union may either be screwed or
socket welded to the pipe! as permitted by the pipe specification.
81
"peci2ication and identi2ication o2 "cre=ed Joints
Nominal Pipe "iEe> Always to be specified. ,;nly sch H: and above pipe to
be threaded -
Thread> &hether 1'T! 1'S! $S'! etc. The only reliable way to identify a
thread is by using a profile gauge.
1ote 1'T > 1'S are -, de#+ thread angle while $S' is )) de#+ thread
angle.
"cre=ed Joints - DoFs and DonFts
DoFs
Take care when unscrewing a joint! even though the system may have been
de3pressurised(
82
The seal on a union type joint breaks as soon as the ring nut is slackened.
Threaded joints continue to seal until the threads finally release giving no
warning of internal pressure. It is there2ore particularl important not to
stand in 2ront o2 plu#s or caps =hen slacCenin# them+
'rior to making a joint! check for thread damage! correct profile and correct
engagement. heck with thread gauge if necessary.
$efore applying any thread compound! a threaded joint should be made up
dry by hand. +or pipe si.es up to 1
1
7
2
inch 1$! ensure that at least < to 8
threads engage.

Threaded joints continue to seal until the threads finally release giving no
warning of internal pressure. It is there2ore particularl important not to
stand in 2ront o2 plu#s or caps =hen slacCenin# them+

'rior to making a joint! check for thread damage! correct profile and correct
engagement. heck with thread gauge if necessary.

$efore applying any thread compound! a threaded joint should be made up

dry by hand. +or pipe si.es up to 1
1
7
2
inch 1$! ensure that at least < to 8
threads engage.
ChecC i2 there are an restrictions on the use o2 PT1E tape+ There ma
?e a total ?an on PT1E tape5 or it ma ?e restricted to lo= pressure
non-haEardous duties or Gust to non-hdrocar?on duties+
I2 usin# PT1E tape5 ensure that you are using @eavy ?uty 'T+6 tape
,:.2mm thick- on the mechanical ,as opposed to instrument- threaded joints.
&rap the tape in a clockwise direction! no more than two layers thick and
starting at the end of the pipe.
I2 usin# a liNuid thread compound5 follow the manufacturer"s
recommendations. Some compounds have restricted use and others re#uire
a setting time.
Thread tape should not be used on Bull Plu#s i.e. ,Testing points on
exchanger no..les.-
&hen wrenching up screwed joints from hand tight! for pipe si.es up to 1
1
7
2
=
1$ at least 4 more threads should be engaged ,at least E to H threads
engaged in total.- +or larger pipe si.es! thread engagement should be
checked from A1S0 $l.2:.1 3'ipe Threads! )eneral 'urpose.
0t may be necessary to use a thread locking compound on the lock nut of
union type joints. This prevents them from loosening due to vibrations.
Thread tape should not be used on Bull Plu#s i.e. Testing points on
exchanger no..les.
&hen wrenching up screwed joints from hand tight! for pipe si.es up to 1
1
7
2
=
1$ at least 4 more threads should be engaged ,at least E to H threads
84
engaged in total.- +or larger pipe si.es! thread engagement should be
checked from A1S0 $l.2:.1 3'ipe Threads! )eneral 'urpose.
0t may be necessary to use a thread locking compound on the lock nut of
union type joints. This prevents them from loosening due to vibrations.
DonFts
?o not cross threads! force screwed joints together or attempt to mate
unmatched threads. A seal will not be made.
?o not make a seal by applying excessive 'T+6 tape to threaded joints. 0f a
seal cannot be made! the threads are probably damaged and new threads
should be cut on a fresh section of pipe.
'T+6 tape should never extend beyond or overhang the first thread on a joint
as tape could shred and enter the fluid system.
Compression 1ittin#s
ompression +ittings are predominantly used on instrument pipework. There are
numerous designs available but that used most by $' for low pressure
instrument duties is the S&A)6F;L double ferrule compression fitting. ;ther
types of compression fittings are used on high pressure and7or hydraulic duties.
The ":AGE6OK compression fitting comprises < parts 3 a nut! a back ferrule! a
front ferrule and a body. &hen making a connection from new parts! the action
of tightening the nut results in both the front and back ferrules swaging the tube.
0n particular! the back ferrule acts as a wedge and forces the front ferrule against
the tube. This swaging process usually re#uires about 1
1
7
<
turns of the nut from
hand tight to achieve.
1o tor#ue is transmitted to the tube when tightening the nut. The tube will
therefore not re#uire restraint and there is no initial strain which would otherwise
weaken the tube.
;nce the compression fitting has been made! it may be repeatedly undone and
retightened with no adverse effects to it"s sealing capability. As the tube will
have already been swaged! only a W turn of the nut from hand tight will be
re#uired to make the seal. 1ote that the front and back ferrules on a correctly
swaged tube ,when dismantled- should both be 2ree to rotate+
0nstrument pipe specifications are available and should be used to specify
material re#uirements in exactly the same manner as with pipe and pipe fittings.
The appropriate Dinstrument piping specification= will be referenced in the piping
specification for a particular pipe class. @ence it is necessary to identify the pipe
class of the pipework to which the instrument fittings are connected.
8<
Compression 1ittin# -
"peci2ication and Identi2ication
1ittin# 3anu2acturer> State the manufacturer and the manufacturer"s
reference code for the particular fitting that you re#uire. 2efer to the
instrument piping specification.
Tu?e OD> A26TT 5etric and imperial compression fittings are incompatible.
2efer to the instrument pipe specification to check which is used.
Tu?e :all ThicCness> 1ormally not re#uired. 0f in doubt about what appears
to be a very thick or thin wall! check with the manufacturer as they normally
set limitations on the tube wall thickness.
88
Pressure> Again! not normally re#uired but #uote if in doubt. ;ther types of
compression fittings will be specified for high pressure applications.
1ittin# 3aterial> 5ust be #uoted and will be as specified in the instrument
piping specification.
1ittin# Bod Connection> ?ependent on the application. A variety of body
connections are available and must be #uoted to complete the description of
the compression fitting. 6.g.( 5ale 1'T straight! elbow or tee connectors!
+emale connectors for parallel pipe thread! unions! reducing unions! etc.
Compression 1ittin#s - DoFs ! DonFts
DoFs
6nsure that the compression fitting is free of dirt or any foreign material. The
tube to be fitted must also be clean. The tube end must be cut s#uare and
any burrs should be removed.
+ollow the manufacturers recommended procedure for tightening up the
fitting when new. Swagelok compression fittings generally re#uire 1.17< turns
of the nut from finger tight to obtain an effective seal. ,Small tubing 2! 4 and
<mm only re#uire a 47< turn.-
;nce tightened! check the gap between the nut and the body of the fitting
with a Swagelok 0nspection )auge. 0f the gauge fits! then additional
tightening of the nut is re#uired.
89
&hen re3tightening a disconnected fitting! the nut will not re#uire as much
tightening as when making the connection from new. Swagelok fittings
re#uire about W of a turn from hand tight to regain the seal. /se the
inspection gauge to check.
5etric and 0mperial compression fittings are incompatible! therefore cheek
which is being used. Swagelok metric compression fittings have a stepped
shoulder machined on the nut hex and the body hex. The letters 55 will also
be stamped on shaped body fittings.
DonFts
?o not combine or mix parts from various compression fitting manufacturers.
The components may have different dimensions and tolerances and a seal
will be difficult to achieve.
1ever turn the fitting body to make up the joint. The body should be held and
the nut rotated.
?o not use stainless steel tubing with brass fittings. The metal tubing
material should either be the same or softer than the fitting material.
?o not use tubing which is scratched! depressed or deformed. Similarly! do
not force oval tube into a fitting. The tube should be cut back to sound
material.
?o not use 'T+6 tape of any other thread sealing compound between the nut
and the body of the compression fitting.
1ever bleed down a system by loosening the compression fitting nut.
Elastomeric O-(in# "eals
This section only applies to ;3rings used on static seals such as bolted covers
and joints. ?ynamic seals! as found on pump shafts for example! are not
covered.
The sealing arrangement on a static seal typically involves a groove cut into the
face of the joint surface and into which the ;3ring is placed. The ;3ring will
stand slightly proud of the groove until axially compressed by the closure cover!
thereby making the seal. ;nce bolted up! application of pressure forces the ;3
ring across the groove and increases its sealing effect. @ard back3up rings may
be used to prevent the ;3ring extruding into the clearance gap between the joint
surfaces.
8E
8H
"election O2 Elastomeric O-(in#s
Selection of 6lastomeric ;3rings AF&ARS needs careful attention. Selection is
normally made by the designer of the joint who will consider both the service
duty and the joint design as follows(
"erDice Dut
1luid5 includin# an contaminants and*or additiDes+ ertain elastomers
may be susceptible to chemical attack for example by @2S! methanol or
glycol.
Always check chemical resistance of a variety of elastomers and plastics.
Temperature ran#e+ 6lastomers have operating temperature ranges outside
which their desirable properties may degenerate. +or example! chemical
hardening at high temperatures! brittleness at low temperatures.
Pressure ran#e+ 1ote that certain operating conditions can produce a Dfull
vacuum= and may re#uire a special joint design.
An transient or cclic conditions5 includin# the num?er o2 ccles+ +or
example! rapid decompression or Dblow3down= may have serious
conse#uences on certain gas permeable ;3rings. Special grades of
elastomer are available where explosive decompression might be a problem.
See Dexplosive decompression damage=.
(eNuired operatin# li2e+ 1ote that o.one! /I light! radioactivity! heat and
oxygen may result in premature ageing and gradual loss of properties even
before installation.
Desi#n o2 Joint
De2ormation o2 the O-rin#+ There is an optimum compression for ;3rings
used in static seals! above or below which permanent deformation and loss of
sealing capability may result.
Hardness o2 the O-rin#+ @ardness of elastomers is measured in units of
Shore A or ? or in 0nternational 2ubber @ardness ?egrees ,02@?-. 0n
general! harder ;3rings are selected for higher pressures and7or to reduce
extrusion% softer ;3rings are selected for lower pressures.
Clearance Gap+ The clearance gap of the joint depends on machining
tolerances! eccentricities and metallic Dbreathing=. 'oor machining may
result in extrusion damage of the ;3ring.
7se o2 BacC-up (in#s+ @ard back3up rings may be specified to reduce or
eliminate ;3ring extrusion! typically for higher pressures and7or softer ;3
rings.
Elastomeric O-rin# 1ailures
8G
The following examples of ;3ring failure may be a result of incorrect ;3ring
specification or poor joint design and manufacture. ;3rings removed from joints
should always be checked for evidence of such failure. +ailed ;3rings should be
kept safe for further investigation by your 6ngineering ?epartment and the ;3
ring manufacturer.
EKtrusion Dama#e+ EKtrusion is characterised ? 9peelin#; or 9ni??lin#; o2
the O-rin# sur2ace+ The O-rin# eKtrudes too 2ar into the clearance #ap and
shears+
9:
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Compression "et 1ailure+ The O-rin# loses itFs Elastomeric memor ! 2lattens+
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EKplosiDe Decompression Dama#e+ 7nder hi#h pressure5 #ases ma di22use
in to the elastomer+ On rapid decompression5 the a?sor?ed #ases
eKpand NuicCl and cause ?listerin# and rupture o2 the O-rin#+
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9<
Elastomeric O-(in#s -
"peci2ication ! Identi2ication
O-(in# 3anu2acturer5 O-(in# Trade Name and Grade> This information
should be specified on the schematic! arrangement drawing or parts list
associated with the e#uipment being maintained.
O-(in# Tpe> +ully moulded ;3rings should always be specified.
O-(in# Dimensions> These will also be specified on the relevant schematic!
arrangement drawing or parts list.
BacC-up (in#s> Should only be used when indicated on the relevant
schematic or drawing. ?imensions and material specification will also be
specified.
"erDice Dut> &hen appropriate! full service details should be provided.
e.g.( +or supply of new e#uipment.
In particular5 serDice dut details should ?e proDided =hen the ori#inal O-
rin# speci2ication is unCno=n or i2 considerin# use o2 a di22erent O-rin#
speci2ication+ The eNuipment manu2acturer must ?e consulted and
con2irmation that the O-rin# is suita?le 2or the serDice dut should ?e
sou#ht+ An proposed material must then ?e endorsed ? our
En#ineerin# Department+
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Installation o2 Elastomeric O-(in#s -
DoFs ! DonFts

DoFs
'rior to installation! check for the correct material specification! trade name
and manufacturer. heck that the ;3ring ,and back3up ring if specified- is the
correct si.e! undamaged and clean. Template gauges are recommended for
checking larger ;3ring si.es.
+ollow the manufacturer"s recommended installation instructions. This
applies to both the ;3ring manufacturer and the e#uipment manufacturer.
heck the condition of the ring groove and any bearing surfaces. 6nsure that
they are thoroughly cleaned with a recommended cleanser and dried before
installation of the ;3ring.
A26T 5any cleaning or degreasing agents may chemically attack the
elastomer.
;3rings may be lubricated only where specified lubricants are recommended
by the supplier.
Always use fully moulded ;3rings.
Take care not to cut! pinch or shear an ;3ring when assembling the joint.
DonFts
1ever force or stretch the ;3ring into a groove for which it is not specifically
designed.
?o not use unmarked ;3rings or ;3rings that have not been stored in the
supplier"s packing.
?o not install an ;3ring with an expired shelf life.
?o not make3up an ;3ring joint if the previous ;3ring showed evidence of
failure. heck with your 6ngineering ?epartment first.
1ever cut ;3rings to si.e and then glue or bond back together.

?o not estimate ;3ring dimensions from the groove dimensions. ;nly use
the schematic! arrangement drawing or parts list for the e#uipment you are
dealing with.
?o not re3use hard back3up rings. 1ew back3up rings must be fitted when
installing new ;3rings.
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