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A technical paper
presented by
James Walker Australia Pty Ltd
Abstract:
Disclaimer:
This information is based on our general experience, but because of factors which are outside our
knowledge and control, no warranty is given or is to be implied with respect to such information. If any
doubt exists, please seek advice from James Walker.
2.0
PURPOSE ....................................................................................................................................... 3
3.0
INTRODUCTION ............................................................................................................................. 3
4.0
SCOPE ............................................................................................................................................ 3
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
Index of Figures
Figure 1- PE stub flange to PE stub flange ............................................................................................................. 4
Figure 2- PE stub flange to Metal flange ................................................................................................................. 5
Figure 3-PE stub flange to metal flange (flat or raised face) ................................................................................... 5
v3(Released)
Document Control
Rev
Revision
date
Summary of Changes
Changes
marked
0.1
14-AUG-14
Initial draft
0.2
18-AUG-14
1.0
01-SEP-14
2.0
10-FEB-15
3.0
03-MAR-15
Glossary
Abbreviation
Definition
ESA
FSA
HDPE
PE
Polyethylene
1.0
The following related documents and standards are referenced in this document.
Reference document
Title
Issue Date(3)
POP007(1)
01-MAR-2006
TN-38(2)
JULY-2011
AS/NZS 4130
2009
AS ISO 9624
2008
ASME B16.5
2013
ASME B16.21
ASME PCC-1
2011
2013
AS/NZS 4331
(ISO 7005)
1995
AS/NZS 4087
2011
AS/NZS 4020
2005
AS/NZS 4623
2008
AS/NZS 2129
ISO 7483
Page 2 of 14
2000
1991
Updated: 03-MAR-2015
v3(Released)
Notes:
1. Available from Plastic Industry Pipe Association of Australia (PIPA) www.pipa.com.au
2. Available from Plastic Pipe Institute (PPI) www.ppi.org
3. Current issue at August 2014
2.0
Purpose
The purpose of this document is to review the various gasket solutions which are now available to suit
Polyethylene (PE) pipe connections.
These are not mandatory requirements but are presented as best practice recommendations when designing
gasket solutions for PE pipe connections.
3.0
Introduction
PE pipe and associated connections are now rated for use in a variety of demanding services, operating
pressures and temperatures; these include water, waste water, potable water, gas and fuel.
It is important to make careful and appropriate gasket decisions to suit the specific requirements for each of
these applications for the same reasons which apply when selecting gaskets for metal flange connections.
Whilst gasket-less connections are possible with these connections it is still common-practice to employ gaskets
between (1) PE to PE stub flange connections, and (2) PE stub flange to metal flange connections. This
document does not discuss gasket-less connections in any detail.
Since these stub flange connections generally employ metallic backing rings which are dimensioned to standard
metallic flange dimensions such as ASME B16.5 one would be forgiven for assuming that the selection of the
companion gasket standard such as ASME B16.21 would also be logical to apply. Unfortunately there are some
key differences in these applications which make these standard gasket dimensions less than optimal in many
PE connections.
It may also be shown that the inside diameter of gaskets has to be considered in relation to various gasket
materials as well as pipe class in some cases.
4.0
Scope
In this document we consider gaskets to suit the two main connection arrangements in use:
1) PE stub flange to PE stub flange (Fig-1) and,
2) PE stub flange to metal flange (flat or raised face) Fig-2
Pipe classifications AS4130 Class PE80 and PE100 across the available range of pipe SDR ratings are
covered.
Various gasket styles such as ring, full face, and drop-in are also discussed here.
Various elastomeric compounds and compressed non-asbestos fibre (CNAF) material options are reviewed in
detail.
Page 3 of 14
Updated: 03-MAR-2015
5.0
v3(Released)
PE Pipe classifications
41
33
26
21
17
13.6
11
7.4
PE80
PN 3.2
PN 4
PN 6.3
PN 8
PN 10
PN 12.5
PN 16
PN 20
PE100
PN 4
PN 6.3
PN 8
PN 10
PN 12.5
PN 16
PN 20
PN 25
6.0
PE Flange connections
There are two common connection methods in use. These are shown in Fig-1 and Fig-2 below and are
discussed in more detail.
Figure 1- PE stub flange to PE stub flange
Fig-1 shows a typical PE stub flange to PE stub
flange arrangement where the two stub flanges are
held together using a pair of metallic backing rings.
Note the relationship of the gasket ID (right) which is
scaled as per ASME B16.21.
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Updated: 03-MAR-2015
v3(Released)
Whilst Fig-1 and Fig-2 specifically reference ASME B16.21 for a gasket comparison the same relationship and
scale will also apply to other flange standards which may or may not have companion gasket standards.
7.0
Metallic backing rings are discussed in detail in POP007. That document provides details of dimensions and
requirements for backing rings according to flange standards listed in table 2 below.
Table 2 - Metallic backing ring flange standards covered in POP007
Standard
Flange Classification
ASME B16.5
Class 150
Companion gasket
standard
ASME B16.21
AS/NZS 2129
Table D
None
AS/NZS 2129
Table E
None
Table 10 or PN10
ISO 7483
Table 11 or PN16
ISO 7483
AS/NZS 4087
AS/NZS 1646
material only
AS/NZS 4087
AS/NZS 1646
material only
In terms of gasket selection the metallic backing ring selection is significant in that the gasket nominal size (DN
or NPS) is actually based on this backing ring DN or NPS and NOT on the pipe nominal size (DN) directly.
Table 3 shows the relationship between pipe DN and metallic backing ring as well as metal flange DN or NPS
for backing rings covered in POP007.
Page 5 of 14
Updated: 03-MAR-2015
v3(Released)
mm
mm
AS/NZS 4087
Backing
ring/flange NPS
(Gasket NPS)
ISO 7005
Backing ring or
flange DN
(Gasket DN)
AS/NSZ 2129
Pipe DN
(Nom pipe
OD)
ASME B16.5
inch
20
15
25
20
32
25
40
32
50
40
63
50
75
65
90
80
110
100
125
100
125
125
140
125
160
150
180
150
200
200
225
200
225
225
250
250
10
280
250
10
315
300
12
355
350
14
400
400
16
450
450
18
450
500
500
500
560
550
560
600
630
600
710
800
20
24
700
800
Page 6 of 14
Updated: 03-MAR-2015
mm
mm
AS/NZS 4087
Backing
ring/flange NPS
(Gasket NPS)
ISO 7005
Backing ring or
flange DN
(Gasket DN)
AS/NSZ 2129
Pipe DN
(Nom pipe
OD)
v3(Released)
ASME B16.5
inch
900
900
1000
1000
8.0
There are three basic styles of gasket to consider for these connections. The following is a discussion of the
advantages and disadvantages of each style. The final selection preference is left up to end users.
Other gasket styles may also exist but are generally of proprietary design and are not discussed here.
End users should carefully consider if this gasket style will be suitable for their
purposes and consider potential difficulty during fitting. Installers must juggle metal
backing rings, studbolts as well as the gasket whilst trying to fit it centrally.
There is a high risk of misalignment with ring style gaskets without careful attention
during installation.
Disadvantages
Very economical
This is the most common gasket style employed and is recommended for all
applications.
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Updated: 03-MAR-2015
v3(Released)
Disadvantages
Easy to fit
Self-centrering
Disadvantages
Self-centrering
9.0
There is of course a wide variety of gasket materials to choose from. The following guide provides some general
information but gasket manufacturers should be consulted for best advice regarding materials for specific
applications.
Table 7 provides a summary of commonly used gasket materials and their properties.
When selecting elastomeric gaskets ensure the elastomer is suitable for all intended media and specify good
quality elastomers between 60-70 Shore A durometer hardness. Poor quality elastomers have poor
compression set characteristics and contain a higher percentage of non-reinforcing fillers. Such elastomers will
compromise the gasket performance and may not be able to support the stated pressure limits listed.
There are many other material options and proprietary gasket designs also available. Unfortunately it is not
possible to review all materials here.
Page 8 of 14
Updated: 03-MAR-2015
v3(Released)
Details
Material type
Units
bar
(MPa)
8 (0.8)
8 (0.8)
8 (0.8)
100 (10)
100 (10)
Deg C
100
110
120
400
350
EPDM
CNAF
Sentinel
INCA
MPa
15
15
MPa
10
10
10
50
50
(2)
(3)
(3)
(3)
1) AppliestoreinforcedandnonreinforcedgoodqualityelastomericsheetmaterialbutNOTspecialised
gasketswithmetalinsertsorotheruniquedesigns.Thesedesignsmaywellbesuitableforhigherpressures
anddifferentoperatingstresses.
2) SentinelhasAGAGasapprovaltoAS/NZS4623Class3upto2,000kPa
3) PotablewaterapplicationsmayrequirespecialgradesofEPDMandmayrequireapprovaltoAS/NZS4020
requirementsinAustralia.Detailsareavailableonrequest.BothSentinelandINCAalsohaveWRASUK
approvalforhot/coldwaterupto85degC.
4) OperatingpressuresforCNAFcanvarybythickness.Maxvaluesshownforinfoonlyandsubstantially
exceedPEpiperatingsanyway.
Gasket material selection may also affect gasket dimensions, in particular the gasket ID. See further details
below regarding gasket ID vs material discussion.
10.0
Gasket dimensions
Unlike metal flange connections where it is quite common to use elastomeric gaskets on flat-face flanges, all PE
stub flange connections need to be considered the same as raised face (RF) flange applications. This is
because the PE stub flange effectively results in gasket contact areas quite similar to raised face applications.
This is so even when a flat face metal flange is used on one side of the connection.
When determining optimum gasket dimensions the following requirements need to be considered:
1) Gasket stress area vs. studbolt stress area ratio
2) Maximum stress requirements for each different gasket material
3) Intrusion into pipe bore in case of PE stub flange to metal flange connections.
Table 8 below provides methods to use when determining gasket dimensions.
Page 9 of 14
Updated: 03-MAR-2015
v3(Released)
Gasket style
Ring style
Notes
Full face,
drop-in
Same as backing
ring OD
No of holes
Full face,
drop-in
Same as backing
ring
Hole dia.
Full face,
drop-in
Same as backing
ring
Gasket ID
ALL styles
Gasket
thickness
ALL styles
Table 9 provides recommended practices when determining the gasket inside diameter.
Table 9-How to determine correct gasket ID
Gasket material
Elastomeric (1)
Max operating
pressure bar
(MPa)
8 (0.8)
PE to PE
connection
PE to metal flange
connection
Use Rule #1
Do not use
Use Rule #2
Use Rule #2
CNAF materials
1.
2.
3.
Asshownintable7,appliestogoodquality,standardreinforcedornonreinforcedsheetmaterialonly.
ThesevaluesexceedmaximumratingofPEpipeandareshownforinformationonly.
Page 10 of 14
Updated: 03-MAR-2015
v3(Released)
When selecting non-elastomeric gasket materials you should consider the thinnest practical gasket material to
suit the flange conditions. In general, we suggest 1.5mm thick gaskets for non-elastomeric materials up to
DN600. However, it must also be recognised and considered for existing installations the potential for a
cumulative error in flange face separation over long pipe runs.
11.0
PPI document TN-38 discusses bolt load/torque requirements for PE stub flanges in detail. This document is
recommended as a guide to determine the bolt load and torque for these applications.
Be aware that TN-38 primarily focuses on gasket-less solutions but also reviews the use of elastomeric gaskets
and is still valid in determining the required bolt loads and stresses when gaskets are used.
Page 11 of 14
Updated: 03-MAR-2015
v3(Released)
Where the gasket material, pipe, flange DN or specific application is outside the scope of TN-38 both PE flange
and gasket manufacturers should be consulted to determine a suitable bolt load solution.
ASME PCC-1 also provides detailed guidelines applicable to installation and gasket stress calculations if
required.
Table 10 shows typical gasket and bolt load/stress values based on using elastomeric gaskets. The loads are
based on targeting the maximum initial gasket stress of 10 MPa (table 7). Note the relatively low bolt stress
values.
Table 11 shows the same data based on using CNAF materials but targeting a nominal gasket operating stress
of 15 MPa also per table 7.
Table 10- Sample gasket stress vs bolt stress data (Elastomeric materials)
Detail
Pipe DN
Units
mm
Bar
(MPa)
mm
Example 1
160
Example 2
160
PE100
PE100
17
17
8 (0.8)
8 (0.8)
PE to PE
PE to PE
150
150
ASME B16.5
ASME B16.5
Class 150
Class 150
Full face
Full face
#1
#2
Gasket ID
mm
140.7
168.3
mm
212
212
mm2
19,751
13,053
ea
Size of studbolts
inch
PE stub flange OD
mm
212
212
mm2
1745
1745
Bolt stress
MPa
112
76
MPa
10
10
MPa
9.3
8.9
No of studbolts
Note:
1)
Page 12 of 14
Updated: 03-MAR-2015
v3(Released)
Table 11- Sample gasket stress vs bolt stress data (CNAF materials)
Detail
Pipe DN
Units
Example 3
160
Example 4
160
PE100
PE100
17
17
16 (1.6)
16 (1.6)
PE to PE
PE to PE
150
150
ASME B16.5
ASME B16.5
Class 150
Class 150
Full face
Full face
#1
#2
mm
140.7
168.3
mm
212
212
mm2
19,751
13,053
ea
Size of studbolts
inch
PE stub flange OD
mm
212
212
mm2
1745
1745
Bolt stress
MPa
184
135
MPa
16.3
18
MPa
15
15
mm
Operating pressure
Pipe connection type
Flange/backing ring DN
mm
(1)
Note:
1) Effective gasket OD is equal to PE stub flange OD for PE-PE connections.
12.0
As may be seen in table 3 above there are multiple examples where the same flange backing ring DN fits
different pipe DN sizes. Therefore, in order to select the correct gasket for each application, the following
minimum information should be supplied when ordering/specifying gaskets:
Essential data
1.
2.
3.
4.
5.
Nominal PE pipe DN
Pipe classification from AS 4130 or pipe standard. I.e.) PE80 or PE100 only
SDR rating of pipe and PE stub flange (these are the same)
Nominal backing ring DN or NPS
Backing ring flange standard selected. Eg) ASME B16.5 Class 150, AS 2129 etc
6. Connection type
a. PE stub flange to PE stub flange (assumed unless stated otherwise)
b. PE stub flange to metal flange (raised face or flat face)
7. Required gasket style. I.e.) Full face ++
8. Required gasket material ++
9. Required gasket thickness ++
Page 13 of 14
Updated: 03-MAR-2015
v3(Released)
Page 14 of 14
Updated: 03-MAR-2015
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James Walker UK
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