When a gasket failure occurs, it can be problematic and cause downtime in your facility. Most gasket failures are due to faulty user installation, according to multiple sources. Typically failures are preventable.
We have a step-by-step guide for your next gasket installation. However, prior to starting your installation, it is important to follow all safety procedures to depressurize, drain, and de-energize your system.
Inspect
When the gasket is removed from the flange, any debris around the sealing surface must be removed. Using a wire brush, remove any embedded material. Be sure not to damage the flange sealing surface by using a grinder or hammer.
Install
The first step to proper installation is to make sure that as you are fitting the pipe and flanges, the mating surfaces come together evenly and plumb. Ensuring the flanges are parallel as they are brought together will create the best seal and provide the best chance of applying a uniform maximum gasket load.
Gasket
The next step in installation is to inspect your gasket for any possible defects, it must be cleanly cut. Then, carefully insert the gasket between the flanges, and be sure that it is centered between the flanges.
Do not apply release agents or joint compounds on the sealing surface of the gasket during a difficult installation. This could cause the now-lubricated gasket to force out from the flange as a result of internal pressure and hydrostatic end forces that are acting on the joint. Alternatively, the material can create a chemical reaction on the gasket and compromise its effectiveness and life expectancy.
When the gasket is in place, with the bolt holes lined up and the flanges have uniform bolt spacing, bring the flanges together. Insert the gasket and “two-hole” the flange—meaning get at least two bolts in two bolt holes. This approach allows you to fine-tune the alignment for the rest of the bolt holes.
If getting the holes lined up proves to be tricky, I recommend purchasing a spud wrench. A spud wrench has a sharp point on one side that you drive into the offset bolt holes and maneuver until they line up.
Bolts
The gasket manufacturer can provide recommended torque valves. To avoid issues, it is important to ensure that bolt stresses created by the recommended torque are within the allowable limits of the bolting materials. You will need a torque wrench to get the bolts to the recommended torque rating.
Lubricate the bolts and tighten them, but do not lubricate the gasket. Most manufacturer recommendations say that gaskets should be installed out of the packaging at room temperature, without lubrication.
But what bolts do you need exactly? Stud bolts will likely be the most popular choice. Stud bolts are a piece of all-thread with nuts on both sides, used in lieu of a hex-head bolt. Stud bolts will be easier to remove for maintenance work and they are less likely to shear.
Creep and relaxation
Be sure to torque the bolts properly and cycle the system, and reevaluate and retighten if necessary to make sure nothing leaks. There can be a period where excessive heat or expansion will put tremendous stress on a joint. When a joint “relaxes” the tension, a leak will start to form.
Understanding the instructions that come with your materials and taking time to pay attention to the details will help to ensure that your installation goes as smoothly as possible. Speak to your local Best Plumbing Specialties sales representative to learn about your material options and find the best fit for your facility.