FOR ENHANCED JOINT INTEGRITY - The Flexitallic …

1 FOR ENHANCED JOINT INTEGRITYThe FLEXPRO gasket has been providing an extremely tight, reliable seal in a wide range of applications throughout Europesince its development in Germany over 89 years ago. Flexitallic is pleased to provide more detailed information on the FLEXPRO gasket included in ASME (rev. 2012), the FLEXPRO gasket is comprised of a concentrically serrated solid metalcore with a soft, conformable sealing material bonded to each face. The soft facing material provides low stress gasket seat-ing, while the serrated geometry of the metal core enhances sealing performance by inducing stress concentrations on thesealing surfaces. The serrations minimize lateral movement of the facing material, while the metal core provides rigidity andblowout FLEXPRO gasket exhibits excellent compressibility and recovery characteristics, maintaining JOINT tightness under pres-sure and temperature fluctuations, temperature differential across the flange face, flange rotation, bolt stress relaxation, andcreep.

2 Suitable from vacuum to extremely high pressure the world safer and cleanerthrough engineered sealing solutionsStyle PNStyle PN FLEXPRO gaskets areselected for use in confined locations,including male and female, tongueand groove, and recessed ZGVariation of the PN FLEXPRO , uti-lizes an integral outer locating ringfor correct gasket positioning withinthe mating flange bolt circle. StyleZG FLEXPRO gaskets are recom-mended for use on standard raisedface and flat face flange ZAThe Style ZA FLEXPRO is a slight vari-ation of the Style ZG. The integralouter locating ring is replaced by aloose fitting independent ring which ispreferred where flange differentialradial thermal expansion may beencountered. These rings may also bespot CONSTRUCTION WITH A SERRATED CORESoft, conformable facingSerrated surface machined on solid metal coreOptional outer ring for centering; can be integral or floating2 IDEAL FOR HEAT EXCHANGER FLANGESA lthough suitable for use on standard ASME flanges in a wide range of difficult applications, the FLEXPRO gasket isproving to be especially suitable as a reliable, cost effective alternative to jacketed gaskets that are commonly used inheat exchanger applications.

3 Use of the Flexitallic FLEXPRO gasket will ensure a reliable seal, from initial hydrotestthrough difficult operating conditions. FLEXPRO gaskets are suitable for use on TEMA flanges, and when required,pass partition ribs can be supplied in any configuration. The FLEXPRO gasket provides a high INTEGRITY , low seatingstress seal, and is ideal for heat exchanger applications with limited bolt load or lighter weight MaterialMax. TemperatureStainless SteelCarbon SteelBrassCopperAluminumMonelNickelIncon el1000 - 1600 F (535 - 870 C)1000 F (535 C)500 F (260 C)600 F (315 C)800 F (425 C)1500 F (815 C)1200 F (650 C)2000 F (1100 C)SHELL SIDETUBE LOCATIONS1. Floating Head2. Shell Cover3. Shell to Tubesheet4. Tubesheet to Channel Box5. Channel Box CoverSTANDARD CORE MATERIALSS tandard core thickness is (nominal); other thicknessesand materials are readily available to suit specific FACING MATERIALSS tandard facing thickness is ; other thicknesses and mate-rials are readily available to suit specific SURFACE FINISH REQUIREMENTSThe ideal flanges surface finish for use with Flexitallic FLEXPRO gaskets is 125 - 250 m-inch MaterialMax.

4 TemperatureSeating Stress at Room (Mpa) (Mpa)Thermiculite Flexicarb Flexible GraphitePTFESoft Metals1800 F (982 C)842 F ( 450 C)500 F (260 C)Per Material (Per material)2500 (17)2500 (17)2500 (17)Per Material (Per material)72500 (500)*72500 (500)*72500 (500)*Per Material (Per material)*While high stresses have been utilized, Flexitallic Engineering should be contacted for operating stresses above 40,000 chat with a Flexitallic or call 800-527-19353 Independent PVRC Testing Confirms Superior TightnessRoom Temperature Tightness (ROTT) Behavior CharacterizationPERFORMANCE IN ROTT TESTSThe results of two ROTT tests conducted at TTRL1on Flexitallic FLEXPRO gaskets are shown inFigure the highest Part A stress level (S5 - 15160 psi),Tp values above 55000 were obtained.

5 A tp of55000 corresponds to a Helium leak rate ofapproximately 1 x 10-6mg/s for an 800 psig B test data indicates that this gasket main-tains superior tightness during stress CONSTANTSThe calculated gasket constants are reported inthe table below, along with computed values ofS100, S1000 and the maximum Tp valueobtained in the ROTT ROTT behavior characterization of a gasketconsists of:- Performing a minimum of two ROTT tests onNPS 4 samples- Treating and reporting ROTT data on the basis of the Tightness Parameter Concept- Calculating the PVRC Gasket constants, Gb, a and Gs, according to the proposed ASTMS tandard- Reporting the gasket constants and character-isticsROTT TEST PROCEDUREThe ROTT test includes a gasket load sequence (5 stress levels, S1 to S5), called Part A, which represents the initial JOINT tight-ening and gasket seating.

6 The maximum stress level (S5) is 15160 psi for metallic gaskets. Part A is interrupted at its threehighest stress levels to run unload-reload sequences, called Parts B1, B2, B3 which simulate JOINT relaxation and each stress level, Helium leakage is measured (for two pressures in Part A and one pressure in Part B).ROTT test data are plotted in the form of Gasket Stress, Sg, vs. Tightness Parameter, Tp, on a log-log scale. The tightnessparameter, Tp, is a measure of the ability of an installed gasket to control its leakage performance in a pressurized flange is proportional to the pressure causing a small leak and inversely proportional to the square of the leak. The higher Tp, thetighter the JOINT . A JOINT that is 10 times tighter than another leaks 100 times less (at the same pressure).

7 GASKET CONSTANTS Gb, a , AND GsThe new PVRC tightness based gasket constants are determined from the results of two or more ROTT tests. Together con-stants Gb and a together define an initial seating performance line. The combined effect of Gb, and a is best representedby the value of STP = Gb x Tpa calculated for typical values of Tp such as 100 or 1000. For example S100 = Gb (100) Gs independently represents operation. Low values of Gb, a , Gs, S100 and S1000 are Testing and Research Laboratory - Ecole Polytechnique of Montreal11010010001000010000010000010000 1000 Gasket Stress, Sg (psi)a = = 387 Note: Applied internal pressure (P) for leakage measurements:P = 800 psi points are represented by unfilled markersP = 400 psi points are represented by filled markersFL09RT01FL09RT02Gs = 14 Part APart B1 Part B2 Part B3 Tightness Parameter, TpTable 1 - PVRC ConstantsTable 2 - ASME Constantsmy22500 psiGbaGsS100S1000 TPMAX387 psi1802 psi3888 psi55000 Figure 1 - ROTT Test ResultsMaking the world safer and cleanerthrough engineered sealing solutions4T3 TightnessThe PVRC developed method for characterizing gasket perform-ance specifies three classes of tightness.

8 T1 (economy), T2(standard), and T3 (tight). A tightness class of T3 represents amass leak rate per unit diameter, of mg/sec-mm. Thisgraph shows that the Flexitallic FLEXPRO gasket achieves atightness class of T3 at the lowest seating stress when com-pared to other types of gaskets. Results are based on PVRC testdata, using a gasket with dimensions of 20 x 21-1/2 diameter,with (20) 1 diameter bolts, and an assembly efficiency of Flexitallic FLEXPRO gasket is ideal for use in applicationswith limited bolt load and lighter weight (mg/s)Gasket Stress (psi) of resolutionCMGF lexitallicFLEXPRO FLEXPRO leaks100 times less20 timesless20 timeslessJacketed12000 CMGFLEXPRO 1000080006000400020000 Gasket StressCycling ComparisonDuring operation, unloading of a bolted-gasketed JOINT can occur due to pressurization, fluctuation in pressure and temper-ature, thermal effects, JOINT relaxation, etc.

9 PVRC test data confirms the superior ability of the FLEXPRO gasket to main-tain tightness under these cyclic loading conditions. As shown in the graph, when gasket stress is reduced from 8000 psito 4400 psi, the Flexitallic FLEXPRO gasket leaks 100 times less than the corrugated metal gasket (CMG). When subse-quently reloaded to a gasket stress of 4400 psi and 8000 psi, the FLEXPRO gasket leaks 20 times less than the CMG. A TIGHTER JOINT IS A SAFER JOINT !HELIUM AT 800 PSILive chat with a Flexitallic or call 800-527-19355 STYLE ZG & ZA To Suit ASME and BS 1560 Flanges Class 150 up to 2500 Dimensions in inches15030040060090015002500 NPSd1d2d31/229/321-5/161-7/82-1/82-1/82- 1/82-1/22-1/22-3/43/41-1/81-9/162-1/42-5 /82-5/82-5/82-3/42-3/4311-7/161-7/82-5/8 2-7/82-7/82-7/83-1/83-1/83-3/81-1/41-3/4 2-3/833-1/43-1/43-1/43-1/23-1/24-1/81-1/ 22-1/162-3/43-3/83-3/43-3/43-3/43-7/83-7 /84-5/822-3/43-1/24-1/84-3/84-3/84-3/85- 5/85-5/85-3/42-1/23-1/444-7/85-1/85-1/85 -1/86-1/26-1/26-5/833-7/84-7/85-3/85-7/8 5-7/85-7/86-5/86-7/87-3/43-1/24-3/85-3/8 6-3/86-1/26-3/86-3/87-1/27-3/8---44-7/86 -1/166-7/87-1/877-5/88-1/88-1/49-1/455-1 5/167-3/167-3/48-1/28-3/89-1/29-3/410116 78-3/88-3/49-7/89-3/410-1/211-3/811-1/81 2-1/28910-1/21112-1/81212-5/814-1/813-7/ 815-1/41011-1/812-5/813-3/814-1/414-1/81 5-3/417-1/817-1/818-3/41213-3/814-7/816- 1/816-5/816-1/21819-5/820-1/221-5/81414- 5/816-1/817-3/419-1/81919-3/820-1/222-3/ 4---1616-5/818-3/820-1/421-1/421-1/822-1 /422-5/825-1/4---1818-7/820-7/821-5/823- 1/223-3/824-1/825-1/827-3/4---2020-7/822 -7/823-7/825-3/425-1/226-7/827-1/229-3/4 ---2222-7/824-7/82627-3/427-5/828-7/8--- ------2424-7/826-7/828-1/430-1/230-1/431 -1/83335-1/2---STYLE ZG & ZA in Accordance with DIN 2697 PN64 Up to PN400 Dimensions in mm64100160350320400 DNd1d2d310224056565667676715254561616172 7277253668828282829210340508810210210210 8118135506210211211811812313315065741221 3714314315317019280901381471531531701902 0710011516217318018020222925612514218821 0217217242274301150165218247257257284311 348(175)190260277287284316358---20021428 5309324324358398442250264345364391388442 488---300310410424458458---------3503404 65486512------------400386535543-------- -------Style ZG & ZAd1d2d3 Dimensional DataMaking the world safer and cleanerthrough engineered sealing solutions6 Proven Performance in the Field.

10 TYPICAL APPLICATIONS:HYDROGEND esign Temperature - 850 FDesign Pressure - 3,000 psiNATURAL GASD esign Temperature - AmbientDesign Pressure - 600 psiHEAT TRANSFER FLUIDD esign Temperature - 575 FDesign Pressure - 290 psiEXHAUST GASD esign Temperature - 1300 FDesign Pressure - 20 psiSTEAMD esign Temperature - 575 FDesign Pressure - 250 psiHYDROGEND esign Temperature - 900 FDesign Pressure - 800 psiSuperior Performance by Design ..Wide Range of MaterialsCore and facing materials to suit almost any applicationReproducible ConstructionAssures consistency from lot to lotEasy to Handle and InstallRigid core facilitates easy handling, less damageWide Pressure RangeSuitable from Vacuum to Class 2500 and higher, reduces inventory requirementsWide Temperature RangeSuitable from cryogenics to 2000 F (1100 C) depending on core and facing materialsLow Seating StressIdeal for light flanges with limited available bolt load, as well as highly loaded flangesConformable SurfacesSoft, conformable surface layers accommodate minor dings, nicks and scratches thatare detrimental to other types of gaskets.