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FLEXPROKAMMPROFILES Flexpro - The versatilegasket with three keyfeatures: compressibility,low stress, convenience.www.flexitallic.com
FLEXITALLICThe Flexitallic Group is the internationalmarket leader in the manufactureand supply of high quality, high valueindustrial static sealing products.About usAs the developer of the spiral woundgasket in 1912, we have built on thislegacy of innovation with revolutionaryproducts including Thermiculite andSigma , The Flange Rescue Gasket winnerof the NACE and Dupont Plunkett Awards,and most recently the ChangeTM Gasket,set to transform the global sealing industry.We have a global network of AlliedDistributors across 30 countries. Thisensures local demand is met quickly,providing a combination of the highestproduct quality and outstanding customerservice.Our extensive and varied productoffering includes spiral wound gaskets,RTJ gaskets, FlexproTM Kammprofiles,sheet materials, dynamic and staticpackings, pipe support and customrubber products. Drawing upon thegroup’s rich history and present dayvalues of leadership, quality, serviceand technology, we are at the forefrontof developing sealing solutions forindustries around the world.In addition to a wide range of products,we also deliver world-class technicalsupport and Joint Integrity training.Our MissionMaking the world safer and cleanerthrough engineered sealing solutions.
Allied distributorsBased on sales and geographic reach, the Flexitallic Grouphas become the global supplier of industrial gaskets.Innovative Product RangeWe have a rich history of innovation,which has seen us lead the industrywith many new products.Over the years, our products have gaineda reputation for quality, reliability andtechnology that is second to none.Customised Engineering SolutionsOur Application Engineering, ProductionEngineering and R&D teams workclosely together to design, develop andmanufacture bespoke sealing solutions.We have been responsible for a numberof truly revolutionary products, includingThermiculite , Sigma and the FlangeRescue Gasket, which ensure we areable to continually meet the ever morestringent requirements of our customers.Our Commitment to QualityWe place great emphasis on maintaininginternational quality standards,and are approved to ISO 9001:2008,ISO 14001:2004 and OHSAS 18001:2007,API 6A and API 17D, to ensure we meetthe highest possible standards for allour products and services.We also invest heavily in test andquality assurance equipment to maintainour reputation for the highest qualityproducts.Our materials are subjected to a widerange of tests as specified by statutoryregulations and customer requirements.These approvals enable our customersto make informed choices as to thesuitability of a product for each andevery application.Inside IndustryWe pride ourselves on not simply supplyingproducts, but by supporting customers witha detailed knowledge of their industry andapplications, so that products and servicesare tailored to their specific needs.This unique approach means that we focuson providing more than just a product, butalso a complete solution that adds genuinevalue to our clients.Global Distribution. Local SupportOur products are distributed through aglobal network of Allied Distributors.These carefully selected distribution partnersare strategically located within their territoryto deliver the best possible service andproducts to our customers. This approachmeans our products and know-how areavailable to the global industries we service.Flexitallic SafeOver the last century, our aggressiveR&D efforts have helped customersbecome Flexitallic Safe. From the firstSpiral Wound Gasket in 1912 to the everevolving applications for Thermiculite ,our goal is to develop materials thatpush the parameters of heat, pressureand chemical resistance.1.
FLEXPRO KAMMPROFILESFlexpro - The versatilegasket with three keyfeatures: compressibility,low stress, convenience.The FLEXPRO gasket has been providingan extremely tight, reliable seal in a widerange of applications globally since itsdevelopment in Germany over 50 years ago.The FLEXPRO gasket is comprised of aconcentrically serrated solid metal corewith a soft, conformable sealing materialbonded to each face. The soft facingmaterial provides low stress gasket seating,while the serrated geometry of the metalcore enhances sealing performance byinducing stress concentrations on thesealing surfaces. The serrations minimiselateral movement of the facing material,while the metal core provides rigidity andblowout resistance.The FLEXPRO gasket exhibits excellentcompressibility and recovery characteristics,maintaining joint tightness under pressureand temperature fluctuations, temperaturedifferential across the flange face, flangerotation, bolt stress relaxation, and creep.Suitable for vacuum to extremely highpressure applications.STYLE PNStyle PN FLEXPRO gaskets areselected for use in confined locations,including male and female, tongue andgroove, spigotted and/or recessed flangearrangements.STYLE ZGVariation of the PN FLEXPRO , utilisesan integral outer locating ring for correctgasket positioning within the flangeassembly bolt circle. Style ZGFLEXPRO gaskets are recommendedfor use in standard raised face and flatface flange assemblies.STYLE ZACOMPOSITE CONSTRUCTION WITH SERRATED CORESoft conformable facingSerrated surface machinedon solid metal coreOptional outer ring for centering;can be integral or floating2. www.flexitallic.comThe Style ZA FLEXPRO is a slightvariation of the Style ZG. The integralouter locating ring is replaced by aloose fitting independent ring whichis preferred in applications wheredifferential radial thermal expansionmay be encountered.
FLEXPRO KAMMPROFILESIdeal for Shell and Tube styleHeat Exchanger Flanges.Although suitable for use on allstandard pipeline flanges in a widerange of difficult applications, theFLEXPRO gasket is proving to bereliable, as a cost effective alternativeto metal jacketed gaskets, that arecommonly used in heat exchangerapplications.Use of the Flexitallic FLEXPRO gasket willensure a reliable seal, from initial hydrotestthrough difficult operating conditions.FLEXPRO gaskets are suitable for use on TEMAflanges, and when required,pass partition ribscan be supplied in any configuration.The FLEXPRO gasket provides a high integrity,low seating stress seal, and is ideal for heatexchanger applications with limited bolt loador less rigid flanges.SHELL SIDETUBE SIDE1GASKET LOCATIONS1. Floating Head 2. Shell Cover233. Shell to TubesheetStandard Core MaterialsStandard core thickness is 3.0mm; otherthicknesses and materials are readilyavailable to suit specific applications.Standard Facing MaterialsStandard facing thickness is 0.5mmor 0.75mm (material dependent); otherthicknesses and materials are readilyavailable to suit specific applications.Flange Surface Finish RequirementsThe ideal flange surface finish for usewith Flexitallic FLEXPRO gaskets is 3.2– 6.4μ – metre Ra (125 – 250 μ – inch Ra).44. Tubesheet to Channel Box55. Channel Box CoverCORE MATERIALMAX. TEMPERATUREStainless Steel535 - 870oCCarbon Steel535oCAluminium425oCMonel 815oCNickel650oC Inconel1100oCTitanium Gr.21095oCDuplex 2205* (UNS S31803)300oC*Duplex is subject to embrittlement between 350 C and 500 CFACING MATERIALThermiculite Flexicarb Flexible GraphiteSigma Virgin PTFESoft MetalsMAX. TEMPERATURE1000oC450oC260oC260oCPer materialSEATING STRESS AT ROOM TEMPMIN. PSI (MPa)MAX. PSI (MPa)2500 (17)2500 (17)2500 (17)2500 (17)Per material72500 (500)*72500 (500)*72500 (500)*72500 (500)*Per material*While high stresses have been utilised, Flexitallic Engineering should be contacted for operating stresses above 40,000 psi.3.
FLEXPRO KAMMPROFILESThe ROTT behavior characterisation of a gasketconsists of: Performing a minimum of two ROTT testson NPS 4” samplesROTT test procedureThe ROTT test includes a gasket loadsequence (5 stress levels, S1 to S5), calledPart A, which represents the initial jointtightening and gasket seating. The maximumstress level (S5) is 15160 psi for semimetallic gaskets. Part A is interrupted atits three highest stress levels to run unloadreload sequences, called Parts B1, B2, B3which simulate joint relaxation andre-tightening. At each stress level, heliumleakage is measured (for two pressuresin Part A and one pressure in Part B).Independent PVRCtesting confirmssuperior tightness,room temperaturetightness (ROTT),behaviourcharacterisation. Treating and reporting ROTT data on the basisof the Tightness Parameter concept Calculating the PVRC Gasket constants, Gb, “a”and Gs, according to the proposed ASTM Standard Reporting the gasket constants and characteristicsConstants Gb, “a”, and GsThe PVRC tightness based gasket constants aredetermined from the results of two or more ROTT tests.Constants Gb and “a” together define an initial seatingperformance line. The combined effect of Gb, and “a”is best represented by the value of STp Tp x Gb x “a”calculated for typical values of Tp such as 100or 1000. For example S100 Gb (100)a. Constant Gsindependently represents operation. Low values of Gb,“a”, Gs, S100 and S1000 are favourable.ROTT test data are plotted in the form ofGasket Stress, Sg, vs. Tightness Parameter,Tp, on a log-log scale. The tightnessparameter, Tp, is a measure of the abilityof an installed gasket to control its leakageperformance in a pressurised flange joint.Tp is proportional to the pressure causinga small leak and inversely proportional tothe square of the leak. Higher the Tp value,the tighter the joint. A joint that is 10 timestighter than another leaks 100 times less(at the same pressure).Performance in ROTT testsThe results of two ROTT tests conducted at TTRL1 onFlexitallic FLEXPRO gaskets are shown in Figure 1.At the highest Part A stress level (S5 - 15160 psi),Tp values above 55000 were obtained. A Tp of 55000corresponds to a Helium leak rate of approximately1 x 10-6 mg/s at a test pressure of 800 psi.Gaskets constantsThe calculated gasket constants are reportedin the table below, along with computedvalues of S100, S1000 and the maximumTp value obtained in the ROTT tests.TABLE 1: PVRC CONSTANTSGbaGsS100S1000Part B test data indicates that this gasket maintainssuperior tightness during stress cycling.FIGURE 1: ROTT TEST RESULTSTp MAX387 psi 0.334 14 psi 1802 psi 3888 psi100000Part APart B1Part B2Part B355000TABLE 2: ASME CONSTANTSNote: Applied internal pressure (P) for leakage measurements:P 800 psi points are represented by unfilled markersP 400 psi points are represented by filled markersy22500 psiGasket Stress, Sg (psi)10000ma 0.3341000Gb 387FL09RT01FL09RT02Gs 141101001000Tightness Parameter, Tp14. www.flexitallic.comTightness Testing and Research Laboratory - Ecole Polytechnique of Montreal10000100000
FLEXPRO KAMMPROFILESCyclic Service ComparisonDuring operation, unloading of abolted-gasketed joint can occur due topressurisation, fluctuation in pressure andtemperature, thermal effects, joint relaxation,etc. PVRC test data confirms the superiorability of the FLEXPRO gasket to maintaintightness under these cyclic loadingconditions. As shown in the graph, whengasket stress is reduced from 8000 psi to4400 psi, the FLEXPRO gasket leaks 100times less than a comparable corrugatedmetal graphite gasket (CMG).A tighter joint is a safer joint!T3 TightnessThe PVRC developed method for characterisinggasket performance specifies three classes oftightness. T1 (economy), T2 (standard), and T3(tight). A tightness class of T3 represents a massleak rate of helium per unit diameter, of 0.00002mg/sec-mm. This graph shows that the FlexitallicFLEXPRO gasket achieves a tightness class ofT3 at the lowest seating stress when comparedto other types of gaskets. Results are based onPVRC test data, using a gasket with dimensionsof 20” ID x 20.5” OD, with 20 x 1” diameter boltsand an assembly efficiency of 0.75. The FlexitallicFLEXPRO gasket is ideal for use in applicationswhere limited bolt load and/or light weight flangesare used.HELIUM AT 800 PSI0.1CMG120000.010.000120 timeslessFlexitallicFLEXPRO 1E-0520 timeslessGasket Stress (psi)Leakage (mg/s)10000FLEXPRO leaks100 times less0.00180006000400020001E-06Limit of XPRO Gasket Stress (psi)5.
FLEXPRO KAMMPROFILESFlange Calculations and Gasket Parameters– EN 1591-1 and EN 13555Driven by national requirements within theEuropean Union for increasing plant efficiencyand reducing fugitive emissions the EuropeanStandard EN 1591-1 was first published in 2001.The Standard outlines a calculation method inwhich strength criteria of the individualmechanical components in a bolted joint namely;flanges, bolts and gasket, and importantly leakagecriteria are satisfied for a particular application.The calculation method adopts the premise thatall gasketed bolted flanged connections leak andrequires the user to specify what a permissiblelevel of leakage is for a particular application. Thisis done via the introduction of the concept of thetightness class. At the time of writing EN 1591-1is the only stand alone standardised calculationmethod that includes both stress analysis andtightness proof of a bolted connection.The calculation requires the input ofdata specific to the particular applicationin question. The required gasketcharacteristics are generated in accordancewith the European standard EN 13555.The test protocol outlined in EN 13555is complex and requires the use of costlysophisticated test equipment.As the leading supplier of technicalsolutions in the field of industrial sealingFlexitallic makes use of the latest innovativematerials technologies and calculationmethodologies to ensure the highest levelsof joint integrity. Gasket characteristics inaccordance with EN13555 are available forwide selection of Flexitallic static sealingproducts. Alternatively Flexitallic canundertake flange calculations in accordancewith EN1591-1 on behalf of the end user.LEAKAGE CURVE - KAMM 316L FG 154x124x4.78mm. Test number 07-1331.00E 00p 40 barT 23 CHe1.00E-01Leak rate 00E-07020406080100120140160Gasket Stress (MPa)GASKET CHARACTERISTICS ACROSS A RANGE OF TEMPERATURES, STRESSESAND PRESSURES, RELATING TO THE FOLLOWING PROPERTIES ARE GENERATED:6. www.flexitallic.comQSmaxMaximum surface pressure that can be imposed on a gasket before failure occursQmin(L)Minimum gasket surface pressure required for leakage class (L) on initial loadingQSmin(L)Minimum gasket surface pressure required for leakage class (L) after off-loadingLNLeakage tightness classes:Tightness Class LN:L1.0L0.1L0.01Specific Leakage Rate (mg.s-1.m-1): 1.0 0.1 0.01PQRCreep relaxation factor. Ratio of the original and final surface pressuresΔeGcChange in gasket thickness due to creepEGElastic unloading modulusαGCoefficient of axial thermal expansionμGStatic friction factor between the gasket and contacting flange face.
DIMENSIONALDATANOMINAL BOREINCHESSEALINGINNERDIAMETERFLEXPRO KAMMPROFILESASME B16.20STYLE ZGSTYLE ZASEALINGOUTERDIAMETERCENTERING RING OUTER DIAMETERMM150 Class300 Class400 Class600 Class900 Class1500 Class2500 Class½1523.133.347.854.1Note (2)54.1Note (3)63.569.9¾2028.739.657.266.8Note (2)66.8Note (3)69.976.212536.647.566.873.2Note (2)73.2Note (3)79.585.91 1/43244.560.276.282.6Note (2)82.6Note (3)88.9104.91 1/24052.369.985.995.3Note (2)95.3Note (3)98.6117.625069.988.9104.9111.3Note (2)111.3Note (3)143.0146.12 1/26582.6101.6124.0130.3Note (2)130.3Note (3)165.1168.438098.3123.7136.7149.4Note 92.3520.7577.9Note te te te te (4)GENERAL NOTESDimensions in mm. Tolerances in mm.Figures stated are for information only. Please refer to the current version of the original standards for dimensional information.NOTES1) Tolerances /- 0.8mm for all diameters2) There is no Class 400 flanges in NPS ½” through NPS 3” (use Class 600)3) There is no Class 900 flanges in NPS ½” through NPS 2.½” (use Class 1500)4) There is no Class 2500 flanges in NPS 14” and larger7.
DIMENSIONALDATAFLEXPRO KAMMPROFILESCovered Serrated Metal Gaskets for Type A and Type B Flanges.EN1514-6STYLE ZGSTYLE ZAOUTER NG RING OUTER DIAMETERSEALING OUTER DIAMETERPN10/40PN64/160 L NOTESDiameter tolerances for Table 1. Up to DN 1000: OD /- 0.4mm. ID /- 0.4 mm/-0. Above DN 1000: OD /- 1.0mm. ID /- 1.0 mm/-0Figures stated are for information only. Please refer to the current version of the original standards for dimensional information.
DIMENSIONALDATAFLEXPRO KAMMPROFILESASME B16.20 Series ASTYLE ZGNOMINAL BOREINCHESSTYLE ERINNEROUTERINNEROUTERDIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETERMM150150300300400400600600900900CENTERING RING OUTER 82.71333.51295.41346.21295.41346.21320.81371.6Note (4) Note (4)1435.11378.01403.41447.8Note 61422.4Note (4) Note (4)1492.31428.81454.21498.6Note 81479.6Note (4) Note (4)1549.41492.31517.71555.8Note 61530.4Note (4) Note (4)1606.61543.11568.51612.9Note 71587.5Note (4) Note (4)1663.71593.91619.31663.7Note 91644.7Note (4) Note (4)1714.51644.71682.81733.6Note (4)GENERAL NOTESDimensions in mm. Tolerances in mm.Figures stated are for information only. Please refer to the current version of the original standards for dimensional information.NOTES1) Sealing ID Nom Bore 26 to 34 tolerances /- 0.8mm and Nom Bore 36 to 60 /- 1.5mm2) Sealing OD Nom Bore 26 to 60 tolerances /- 1.5mm3) Centering Ring OD tolerances /- 0.8mm4) There is no Class 900 Flange in NPS 50 and above.9.
DIMENSIONALDATAFLEXPRO KAMMPROFILESASME B16.20 Series BSTYLE ZGNOMINAL BORESTYLE ERINNEROUTERINNEROUTERDIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETER DIAMETERCENTERING RING OUTER 295.41346.21320.81371.6Note (4) Note (4)1357.41419.41403.41447.8Note 61422.4Note (4) Note (4)1408.21470.21454.21498.6Note 81479.6Note (4) Note (4)1463.81530.41517.71555.8Note 61530.4Note (4) Note (4)1514.61593.91568.51612.9Note 71587.5Note (4) Note (4)1579.61655.81619.31663.7Note 91644.7Note (4) Note (4)1630.41706.61682.81733.6Note (4)GENERAL NOTESDimensions in mm. Tolerances in mm.Figures stated are for information only. Please refer to the current version of the original standards for dimensional information.NOTES1) Sealing ID Nom Bore 26 to 34 tolerances /- 0.8mm and Nom Bore 36 to 60 /- 1.5mm2) Sealing OD Nom Bore 26 to 60 tolerances /- 1.5mm3) Centering Ring OD tolerances /- 0.8mm4) There are no Class 900 flanges NPS 50" and above.10. www.flexitallic.com
DIMENSIONALDATAFLEXPRO KAMMPROFILESEN 12560-6STYLE ZGNOMINAL PIPE SIZEINCHESMMSTYLE ZASEALING ELEMENTINNERDIAMETEROUTERDIAMETERCENTERING RING OUTER DIAMETER150 Class300 Class400 Class600 Class900 Class1500 Class2500 69.869.869.876.276.282.51 1/43244.460.373.079.479.479.485.785.7101.61 8.9101.6108.0108.0108.0139.7139.7142.82 8098.4123.8133.4146.1146.1146.1165.1171.5193.73 5-GENERAL NOTESDiameter tolerances:Up to 1000mm OD 0/-0.4mmID 0.4mm/-0Above 1000mm OD 0/-0.1mmID 1.0mm/-011.
HYBRIDAND SPECIALDESIGNSStandard Flexpro Design ProfileWhenever possible Flexitallic recommendthe use of a single piece constructionserrated core (no welds), however, inmany instances the size of gasket requiredis larger than the standard commerciallyavailable sheet material. In these instances,strip material is ring rolled and weldedtogether using the minimum number ofwelds possible. Flexitallic ensure thatthe ends of the ring-rolled metal stripare carefully aligned, both verticallyand horizontally, before full penetrationfusion welding. This process eliminates anypotential leakage paths in the weld locationand minimises the heat affected zone.After careful dressing of the weld concentricserrations are machined on the ring. Thiseliminates any potential high and/or lowspots in the weld area.Lower cost manufacturing routes involvingring-rolling and welding of pre-serratedmetal strip, can result in the integrity ofthe gasket being compromised (leakagepaths at weld locations).Flexitallic processes eliminate potentialleakage paths at weld location.12. www.flexitallic.comPass BarsThe Flexpro kammprofile section iscommonly supplied in pass bar formand incorporated into the tube sideof multi-pass heat exchanger gaskets.Serration ProfilesFlexitallic can manufacture Flexpro gaskets withvarious serration profiles. The standard Flexitallicshallow profile has been designed to effect a highintegrity seal when covered with any one of a rangeof facing materials and thicknesses. Other serrationprofiles as defined by different international orcustomer standards are available.Special ShapesFlexitallic have designed and built a number of serrationprofiling machine tools that provide the capabilityof machining complex shapes while maintaining theconcentric serrations on the sealing faces. Theseshapes can include oval, obround, rectangular andirregular shapes which are often required for manholes,special access door seals and fin fan cooler box covers.The Flexpro core can be supplied in a wide rangeof thicknesses from 2.0mm upwards.The FlexproT design is especially suited for usein connections with narrow radial widths commonlyfound in fin fan plug gaskets and other applicationswhere space is limited such as floating head andvalve body and bonnet locations.In addition to complex shapes, Flexitallic havesuccessfully provided Flexpro kammprofile gasketsfor use on misaligned flanged connections. These‘wedge’ shaped gasket are machined to meet aspecific misalignment angle.Special shapes.Hybrid DesignsFor difficult sealing applications, hybridtechnology can be applied to provide a highintegrity assembly. Flexitallic can providesealing solutions where Flexpro sealingtechnology is combined with other gasketstyles such as spiral wound and Changegaskets. The metal core of the Flexpro section of the gasket provides additional sealintegrity, compression limitation and rigidity.For difficult and special applicationsplease contact the Flexitallic ApplicationsEngineering team.Re-Facing Flexpro GasketsTypically a gasket is used only once, however,when using large diameter or expensive corematerial it may be cost effective to re-faceand re-use the Flexpro gasket. This servicecan provided by Flexitallic or undertakenon site by suitable personnel followingappropriate training.Special shapes.
SUPERIORPERFORMANCEBY DESIGNWHY FLEXPRO KAMMPROFILE GASKETS?Proven DesignMany years of proven success in sealing difficult applications.Superior SealingTightness and SafetyCorrect material selection provides longer service life, no need to ‘hot torque’,reduced emissions and reduced maintenance requirements.Low Seating StressIdeal for light flanges with limited bolt load, as well as highly loaded flanges.Different ShapesFlexitallic production methods provide the capability of manufacturing a wide rangeof sizes in circular and non-circular shapes to suit a wide range of flange types.Wide Rangeof MaterialsFlexproTM gasket metal cores and soft facings are selected from a wide rangeof materials to suit specific applications.Wide Pressure RangeSuitable for use on all standard flange pressure classes and norms.Wide Temperature RangeSuitable for use in cryogenic service up to 1000 CConformableSealing SurfacesThe soft conformable sealing faces of the FlexproTM gaskets, aremore tolerant to smooth and or damaged flange sealing faces.ReproducibleConstructionThe Flexitallic manufacturing processes provide a highly repeatable processfrom one manufacturing batch to another.Easy to Handleand InstallThe rigid and stable core of the FlexproTM gasket facilitates easy handlingand installation, with reduced risk of damage to the gasket.Fire SafeMaterial specific, FlexproTM gaskets are API-6FB Fire Safe.Re-usableFlexproTM gaskets can be re-faced and re-used.Replaces DoubleJacketed GasketsFlexproTM gaskets are a direct replacement for double jacketed gaskets.Note: Where Nubbins (stress raisers) are present, please check withFlexitallic Applications Engineering Team.Space LimitationsFlexproTM gaskets can be manufactured with narrow seal land widthsCost EffectiveLonger service life, less maintenance, reduced emissions.13.
UNITED KINGDOMFRANCEGERMANYFlexitallic UK LtdSiem Supranitea Flexitallic CompanyFlexitallic GmbHScandinavia MillHunsworth LaneCleckheatonWes
mg/sec-mm. This graph shows that the Flexitallic FLEXPRO gasket achieves a tightness class of T3 at the lowest seating stress when compared to other types of gaskets. Results are based on PVRC test data, using a gasket with dimensions of 20" ID x 20.5" OD, with 20 x 1" diameter bolts and an assembly efficiency of 0.75. The Flexitallic
