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Jjenco www.jjenco.com PerfectSeal Constant Seating Stress Gaskets A Revolutionary Approach To Improved Flange Sealing TECHNICAL TUTORIAL FOR ENGINEERS.

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Presentation on theme: "Jjenco www.jjenco.com PerfectSeal Constant Seating Stress Gaskets A Revolutionary Approach To Improved Flange Sealing TECHNICAL TUTORIAL FOR ENGINEERS."— Presentation transcript:

1 jjenco PerfectSeal Constant Seating Stress Gaskets A Revolutionary Approach To Improved Flange Sealing TECHNICAL TUTORIAL FOR ENGINEERS JJENCO, Inc. University Research Park Mallard Creek Road | Suite 300 | Charlotte | North Carolina | | USA |

2 jjenco Introduction The PerfectSealEOS constant seating stress gasket: Does not rely upon (i) highly-trained assembly technicians, (ii) properly calibrated tooling, (iii) complex flange tightening patterns, (iv) time- consuming multiple flange tightening passes, or (v) correct piping alignment in order to achieve a perfect seal every time Cannot be misinstalled, regardless of flange orientation Is at least 7X faster to install than conventional gaskets, even on small 8- bolt flanges Is a direct replacement for all semi-metallic gaskets, including spiral- wound gaskets (SWG) and kammprofile gaskets Is immune to (i) radially-inward buckling (RIB), (ii) foreign material cast- off into the process fluid, (iii) flow-induced gasket degradation, (iv) system vibration and (v) thermal transients Is the least expensive semi-metallic gasket solution when gasket installation costs are included Can be inexpensively refurbished and reused Copyright © JJENCO, Inc All Rights Reserved. 2

3 jjenco Sealing Issues Conventional Gasket Products Product Issues Unknown or imprecise gasket factors Compression Variability (SWG) Wrong Gasket for Application Spent After Single Use Calculation Errors Required Seating Stress Required Fastener Preload Friction Estimate (Nut or K Factor) Required Torque Value Tooling Issues Torque Wrench Accuracy Calibration Errors Off-Axial End Effectors Incorrect Torque Wrench Setting Assembly Issues Incorrect Wrench Reading (Dial/Beam) Improper Torquing Technique Insufficient Fastener Lubricant Improper Lubrication Placement Poor Fastener Thread or Bearing Surface Improper Tightening Sequence Piping Misalignment Uneven Gasket Loading Insufficient Finishing Passes In-Service Issues Soft Joint Assembly >>CR Plant Thermal Cycles >>CR High System Vibration >>CR Radially-Inward Buckling (SWG only) Foreign Material Intrusion [to System] External Blowout Environmental Degradation (eg. Fire) Process Degradation (eg. Oxidation) SWG = Spiral Wound Gasket CR = Creep Relaxation > Loss of Bolt Stress 3 Copyright © JJENCO, Inc All Rights Reserved.

4 jjenco Sealing Solutions PerfectSealEOS Gaskets Product Issues Unknown or imprecise gasket factors Compression Variability (SWG) Wrong Gasket for Application Spent After Single Use Calculation Errors Required Seating Stress Required Fastener Preload Friction Estimate (Nut or K Factor) Required Torque Value Tooling Issues Torque Wrench Accuracy Calibration Errors Off-Axial End Effectors Incorrect Torque Wrench Setting Assembly Issues Incorrect Wrench Reading (Dial/Beam) Improper Torquing Technique Insufficient Fastener Lubricant Improper Lubrication Placement Poor Fastener Thread or Bearing Surface Improper Tightening Sequence Piping Misalignment Uneven Gasket Loading Insufficient Finishing Passes In-Service Issues Soft Joint Assembly >>CR Plant Thermal Cycles >>CR High System Vibration >>CR Radially-Inward Buckling (SWG only) Foreign Material Intrusion [to System] External Blowout Environmental Degradation (eg. Fire) Process Degradation (eg. Oxidation) SWG = Spiral Wound Gasket CR = Creep Relaxation > Loss of Bolt Stress 4 Copyright © JJENCO, Inc All Rights Reserved.

5 jjenco Presentation Overview This self-paced technical tutorial is intended to: Explain the revolutionary constant seating stress gasket concept Illustrate the application of that concept to flange joint assembly Showcase different styles of the PerfectSeal gasket for specific applications Present test data and field demonstration experience Compare performance vs. conventional semi-metallic gaskets Highlight the benefits of constant seating stress gaskets over traditional gasket technologies in real-world applications Demonstrate the cost-benefit of using PerfectSeal gaskets compared to conventional gaskets This tutorial should take approximately 25 minutes to complete Copyright © JJENCO, Inc All Rights Reserved. 5

6 jjenco UNDERSTANDING THE CONSTANT SEATING STRESS GASKET CONCEPT SECTION I Copyright © JJENCO, Inc All Rights Reserved. 6

7 jjenco What is a Constant Seating Stress Gasket? A constant seating stress gasket is defined by two common characteristics: The initial seating stress of the sealing material achieved on assembly does not change appreciably over time The seating stress of the sealing material is relatively uniform radially across the entire sealing area JJENCO holds the patent on constant seating stress gasket technology Constant seating stress gaskets are only available directly from JJENCO 7 Copyright © JJENCO, Inc All Rights Reserved.

8 jjenco Why is Constant Seating Stress Important? Gasket leakage occurs primarily due to one of the following 6 reasons: Flange sealing surfaces too defective to achieve a seal Initial gasket seating stress too high Initial gasket seating stress too low Initial gasket seating stress sufficient to achieve a seal, but gasket creep relaxation leads to loss of seating stress over time System conditions (thermal cycles, high vibration, etc) cause transient or permanent reduction in gasket stress enabling leakage to occur Gasket sealing material not compatible with environmental or process conditions Assuming the sealing surfaces are acceptable and the sealing elements are compatible with the process fluid, PerfectSeal constant seating stress gaskets can mitigate all remaining factors 8 Copyright © JJENCO, Inc All Rights Reserved.

9 jjenco Simple Design Premise The design premise for the PerfectSealEOS gasket recognizes that: A specific amount of gasket seating stress is needed in order to create an effective seal between two flange faces Gasket stress tends to change over time, primarily due to the gasket sealing materials continued response [creep relaxation] to the external force used to create the initial seal, or due to other forces resulting from thermal cycling, vibration, etc If you can achieve the initial seating stress necessary to achieve a seal, and control other factors that can change that seating stress over time, then in-service leakage can be averted in most cases 9 Copyright © JJENCO, Inc All Rights Reserved.

10 jjenco Achieving Correct Gasket Stress Flange deflection – also known as flange rotation – occurs at the outer flange circumference in response to increasing preload of the fasteners during flange assembly Finite element analysis (FEA) can accurately predict the degree of flange deflection that occurs at various radial distances from the flange axis at a given bolt preload for a specified flange size, material and pressure class. Therefore, flange deflection can be used in lieu of applied bolt torque to accurately determine required gasket tightness The PerfectSealEOS gasket profile models flange deflection predicted for a desired preload, making ALL assembly factors associated with achieving the target bolt preload unimportant Copyright © JJENCO, Inc All Rights Reserved. 10

11 jjenco Maintaining the Correct Gasket Stress Creep relaxation of the gasket sealing material is the main cause of loss of gasket seating stress in service Gasket creep occurs as the sealing material seeks to move from a region of higher stress to a region of lower stress, thereby causing an overall reduction in peak gasket stress A leak may result if the peak gasket stress drops below the threshold necessary to maintain the seal between the flanges By fully containing the sealing material within opposing channels on either side of the gasket carrier ring, creep cannot occur in service, thereby self-mitigating the opportunity for a leak to occur Copyright © JJENCO, Inc All Rights Reserved. 11

12 jjenco GENERAL APPLICATION TO FLANGED JOINTS SECTION II Copyright © JJENCO, Inc All Rights Reserved. 12

13 jjenco PerfectSealEOS General Description The PerfectSeal gasket is comprised of a carrier ring (20) and a sealing material elements (22) The carrier ring has three important features: Inner pivot point (30) Inner compression stop (32) Visual Compression Indicator (40) The sealing elements can be any compressible material (e.g., expanded graphite, vermiculite, expanded polytetraflouroethylene, etc.) as appropriate to the application Copyright © JJENCO, Inc All Rights Reserved. 13

14 jjenco On Assembly As the fasteners (16) are tightened, the flange faces (10A, 10B) begin to compress the sealing elements (22) into their respective channels (24) of the carrier ring and ultimately contact the inner pivot point (38) of the carrier ring Continued tightening of the flange fasteners causes normal flange rotation to occur, thereby further compressing the sealing elements into their respective channels A proprietary process controls the compression of the sealing elements into their respective channels Copyright © JJENCO, Inc All Rights Reserved. 14

15 jjenco At Full Compression As the flange faces rotate* about the inner pivot point, they finally engage the inner compression stop (32) The sealing elements are fully compressed, resulting in achievement of the desired gasket seating stress The sealing elements are fully contained, therefore no change in gasket stress can occur in service The sealing elements are also completely protected from both the internal process flow and external environmental factors Copyright © JJENCO, Inc All Rights Reserved. 15 *flange rotation exaggerated for illustration

16 jjenco Achieving Uniform Stress Due to flange rotation, gasket seating stress generally increases with the distance from the axial centerline of the flange This results in the achievement of the target seating stress only at the outer edge of the sealing area – the actual gasket stress over the majority of the sealing area is less By matching the angle of the gasket profile with the calculated degree of flange rotation for a given flange size, pressure class, and material, the desired seating stress can be achieved over the entire sealing area – not just at the gaskets outer edge Copyright © JJENCO, Inc All Rights Reserved. 16

17 jjenco The Visual Compression Indicator By calculating the degree of flange rotation occurring at two points, the outer compression stop (40) and the inner compression stop (32), the outer compression stop thickness can be sized to provide a positive visual indication for the assembly technician that the flange faces have positively engaged the inner compression stop thus fully compressing and capturing the sealing elements in their grooves This outer compression stop also makes the use of calibrated assembly tooling, complex bolt tightening patterns, and sequential finishing passes completely unnecessary, as overcompression of the gasket cannot occurr Copyright © JJENCO, Inc All Rights Reserved. 17

18 jjenco Installation Benefits Sealing element channel prevents crushing or overcompression when inserting gasket, aligning flanges, or tightening fasteners The outer compression stop enables one-pass at 100% tightness, rotationally-sequential, tightening of fasteners Copyright © JJENCO, Inc All Rights Reserved Single Pass Tightening in Sequential Rotation Regardless of Flange Size

19 jjenco APPLICATION CONSIDERATIONS SECTION III Copyright © JJENCO, Inc All Rights Reserved. 19

20 jjenco PerfectSealEOS Style Ideal for all raised and flat face flanges Carrier ring extends outward of the bolt circle Provides real-time proper compression indicator to the assembly technician Prevents misinstallation or gasket misalignment from occurring, regardless of flange orientation Unique bolt hole configuration improves ability to insert fasteners without perfect flange alignment Copyright © JJENCO, Inc All Rights Reserved. 20

21 jjenco PerfectSealCRG Style Ideal for specific flanges Male-female Tongue and groove Eliminates flange fit and tolerance concerns Sealing element protected from process flow degradation Can be manufactured with or without exterior alignment ring Copyright © JJENCO, Inc All Rights Reserved. 21

22 jjenco In-Service Performance Impossible to: Cast-off foreign material into plant systems or components (e.g., no radially-inward buckling (RIB) as with spiral- wound gaskets) Inadvertently crush the gasket due to overcompression Leak due to plant thermal cycles or high system vibration Degrade sealing elements due to process flow impingment Impact sealing element performance by direct external contact Copyright © JJENCO, Inc All Rights Reserved. 22

23 jjenco Application Specifications Carrier ring normally made from 304/316 stainless steel, but can be manufactured from any appropriate material according to client requirements Standard bolt preload emulation is 45ksi, but can be manufactured to emulate bolt preloads from ksi, according to client requirements JJENCO has FEA design data available for ASME B16.5 carbon and stainless steel flanges: RFWN flanges in all pressure classes and sizes from RFSW flanges in all pressure classes and sizes from Other flange types or configurations available (additional design fee applies) Sealing elements are normally expanded graphite, expanded PTFE, or vermiculite, but can be made from any compressible sheet material according to client requirements Copyright © JJENCO, Inc All Rights Reserved. 23

24 jjenco PERFORMANCE DATA SECTION IV Copyright © JJENCO, Inc All Rights Reserved. 24

25 jjenco Creep Relaxation Comparison PerfectSealEOS gasket (red) vs. all other semi-metallic gaskets, including: Spiral-wound gaskets (SWG) Kammprofile gaskets Semi-metallic sheet gaskets Demonstrated less than half the creep (>24hrs) of the best gasket on the market Less creep = less chance of leakage in service Copyright © JJENCO, Inc All Rights Reserved. 25

26 jjenco Comparison to CG Style SWG Industry testing proves that torque required to compress spiral-wound gaskets (SWG) can vary widely between gaskets CG-style* SWG without inner ring can creep in-service, resulting in leakage CG-style SWG are prone to radially-inward buckling (RIB) of their windings that can introduce foreign material into system causing damage to components and system operability concerns Most concerning, not all RIB- degraded SWG in service result in an identifiable leak Copyright © JJENCO, Inc All Rights Reserved. 26 Multiple catastrophic buckles with filler material completely washed out and winding material extending well into the flow path One of several pieces of SWG metal winding material removed from tube bundle of steam generator during routine inspection *The CG designation is used here as a generic identifier for a SWG possessing an outer compression stop ring, but no inner stop ring, and should not be construed to represent any particular manufacturer

27 jjenco Comparison to CGI Style SWG CGI-style* SWG can reduce creep relaxation However, due to the inability of CGI-style gaskets to relieve stress by moving radially inward: The same torque levels used for CG-style SWG can cause extreme radial loads in the gasket sufficient to seriously deform the gasket Or, cause general deformation and buckling of the inner ring itself Copyright © JJENCO, Inc All Rights Reserved. 27 *The CGI designation is used here as a generic identifier for a SWG possessing both an outer and inner compression stop ring and should not be construed to represent any particular manufacturer Illustration of severe CGI-style gasket deformation Evidence proving generalized inner ring buckling can occur

28 jjenco Comparison to Kammprofiles Kammprofile gaskets represent the best of the best among semi-metallic gaskets, with respect to creep resistance However, as with SWG, all kammprofiles perform differently Using identical test equipment and procedures, the PerfectSealEOS gasket (red) is proven to creep 60% less than the best available kammprofile gasket In addition, research shows that kammprofile gaskets also vary in their ability to seal minor surface defects in flange face finish – making excellent sealing surfaces a prerequisite for success Copyright © JJENCO, Inc All Rights Reserved. 28

29 jjenco Field Test Example Demonstrated in 4-Class 150 service water system flange at Duke Energy Riverbend fossil station Installed under blind flange by one technician in under 45-seconds using standard combination wrench Inspected after 1-hour at system T/P with no leaks Copyright © JJENCO, Inc All Rights Reserved. 29

30 jjenco COST BENEFIT CASE SECTION V Copyright © JJENCO, Inc All Rights Reserved. 30

31 jjenco Cost Benefit Considerations Unit Cost basis is NOT a smart procurement strategy for parts performing a critical function Cost of Ownership procurement strategy for critical parts takes into account: Installation costs Cost benefits of increased service reliability and availability Future maintenance costs Total Cost of Ownership also takes into account future avoided costs Copyright © JJENCO, Inc All Rights Reserved. 31

32 jjenco Initial Cost-of-Ownership* 32 Copyright © JJENCO, Inc All Rights Reserved. *4-in Class 150 gasket

33 jjenco Subsequent Reinstallation Cost* 33 Copyright © JJENCO, Inc All Rights Reserved. *4-in Class 150 gasket

34 jjenco Potential Avoided Costs Production Penalties Forced plant outage, outage extension, production reduction Replacement Production e.g., replacement power Maintenance Effort Radiation Exposure (nuclear only) Third-Party Services Leak sealant injections, environmental cleanup, flange remachining, etc. Consequential System or Component Damage Regulatory Fines Response to Regulatory Scrutiny Copyright © JJENCO, Inc All Rights Reserved. 34

35 jjenco CONCLUSION SECTION VI Copyright © JJENCO, Inc All Rights Reserved. 35

36 jjenco Direct Benefits Simpler Tooling – No need to rely upon torque wrenches, stud tensioners, or other calibrated tooling Simplicity of Installation– No complicated assembly patterns, multiple tightening passes Speed of Assembly – Proven at least 7X faster to install on even small 8-bolt flanges Reduced Training – Technicians require limited training to assemble flanged joints successfully Increased protection from environmental- (e.g., fire, etc.) and process-induced degradation No Possible Foreign Material introduction to system Reusable Carrier Ring dramatically reduces future replacement costs Increased Personnel Safety during installation and in-service Potential to Reduce Personnel Radiation Exposure (nuclear) 36 Copyright © JJENCO, Inc All Rights Reserved.

37 jjenco Indirect Benefits Simplified job planning Reduced risk of Future maintenance requirements Collateral or consequential equipment damage Production losses attributable to leakage events Replacement power acquisition (power industry) Potential for reduction in insurance costs Reduced gasket inventory Reduced maintenance administrative burden Increased availability of plant staff Reduced potential for regulatory scrutiny due to leaks 37 Copyright © JJENCO, Inc All Rights Reserved.

38 jjenco Conclusion The constant seating stress gasket design: Uses commonly accepted materials Is based upon simple, proven principles aggregated in a novel manner It should be easy to install and require no follow-on maintenance It is the least expensive gasket solution when gasket installation costs are included It provides both immediate and future benefits in terms of Personnel safety Plant availability and reliability Total cost of ownership 38 Copyright © JJENCO, Inc All Rights Reserved.

39 jjenco Maintenance Self-Assessment Do you have gasket leaks at your site? If so, is your Maintenance department using PerfectSeal constant seating stress gaskets? If not, Why Not? Copyright © JJENCO, Inc All Rights Reserved. 39

40 jjenco For More Information… To obtain: Information on purchasing PerfectSeal constant seating stress gaskets, or Subject-matter expertise for fluid sealing issues… Copyright © JJENCO, Inc All Rights Reserved. 40 John M. Jenco President Research, Technology & Consulting University Research Park | Prosperity Place on Mallard Creek Mallard Creek Road | Suite 300 | Charlotte | | USA (T) | (F) |


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