Increased plant availability through improved load retention of seals in chemical applications.
Different surface pressures for different gaskets pose a problem when mounting seals. Mounting the seals with the correct bolt force causes difficulties for many users. And there are more challenges in the chemical industry that require solutions.
Seals protect the media in chemical processes from external influences and contamination, and prevent emissions. Their sealing effect therefore has an immense influence on the quality of the chemical products, on the safety of the plant, and on the economic efficiency of production.
The challenges that seals pose to users can be summarised as follows, according to a survey by Garlock:
- 28% of the users complain about the wrong bolt force. They have difficulties mounting the gaskets with the correct bolt force because different gaskets require different surface pressures and thus different tightening torques.
- 21% would like to see reduced creep. This would lead to less need for re-torquing.
- 21% would like better sealing. Also sealing with lower surface pressure.
- 14% struggle with problems during installation. These are mostly installation errors that lead to damaged seals and equipment.
- 14% experience leakages due to leaking seals. Especially when carrying aggressive and corrosive chemicals.
To solve these problems and meet the challenges, it is recommended to use GYLON EPIX® from Garlock.
GYLON EPIX® is a family of gaskets that effectively seals a wider range of applications and is more forgiving of errors during the installation process. GYLON EPIX® allows users to save valuable machining time, reduce rework, and lower costs, helping to keep on schedule and on budget.
Improved load retention
GYLON EPIX® has a hexagonal surface profile that provides the torque retention and blow-out resistance of a thin gasket while offering the conformability of a thicker gasket.
Patented hexagonal surface texture
The patented surface texture ensures excellent sealing and adaptation even to imperfect flange surfaces.
GYLON EPIX® is made from the same PTFE material as the classic GYLON® products. This eliminates the need for most customers to qualify the GYLON EPIX® products.
With a universal thickness of 2.4 mm (3/32″), there is no need to stock a variety of material thicknesses with different stress requirements. This leads to a reduction in stock and better sheet utilisation. In addition, time and effort to create and revise factory standards is reduced.
GYLON EPIX® made by Garlock
The innovative GYLON EPIX® demonstrates superior functionality by combining the traditional properties of GYLON® and an innovative surface design. It is suitable for a wider range of applications than conventional PTFE seals. In addition, GYLON EPIX® offers the sealing and load retention properties of 1.6 mm material and the conformability of 3.2 mm. The hexagonal profile allows for improved compressibility and recovery. The profiled surface reduces the contact area during initial compression to concentrate the compressive force of the flange for improved sealing capability. This creates zones of higher density in the material, resulting in less leakage and creating a “multi-barrier”. In addition, defective areas on the flange surface can be “isolated” and “encapsulated”.
The test: Conventional PTFE vs. GYLON EPIX®
GYLON EPIX® and a traditional full face gasket were installed in a 3”-150# flat face flange at 120 ft.lbs. with pressure sensitive film. The film revealed that the traditional material saw heavier loading near and around the bolts, and lighter loading at the points furthest from the bolts. The GYLON EPIX® was able to distribute the load more evenly and prevent the low loading phenomenon.
|Traditional restructured PTFE||GYLON EPIX®|
The pressure sensitive film was then analyzed with special software that translates the various shades of red into a full color spectrum that provides a better visualization of the stresses that were developed on each of the gaskets. Again, while the traditional gasket saw areas of lower stress (green and blue areas), the hexagonal pattern in the GYLON EPIX® concentrated and distributed the stress more evenly across the entire gasket.
|Traditional restructured PTFE||GYLON EPIX®|
GYLON EPIX® Styles
GYLON EPIX® Style 3501-E is a high performance, silica filled PTFE sheet material designed for use with strong acids, solvents, hydrocarbons, and other aggressive media. GYLON EPIX® Style 3501-E withstands a wide range of chemicals for extended service in a wide variety of applications.
GYLON EPIX® Style 3504 is a high performance, aluminosilicate microsphere filled PTFE sheet material designed for use in moderate concentrations of acids, and caustics, as well as hydrocarbons, refrigerants, and more. GYLON EPIX® Style 3504 withstands a wide range of chemicals for extended service in a wide variety of applications.
GYLON EPIX® Style 3510 is a high performance, barium sulfate filled PTFE gasketing material. GYLON EPIX® Style 3510 is designed for use where initiating and maintaining an extremely tight seal is critical; these applications include: strong caustics and moderate acids, chlorine, gases, water, steam, hydrocarbons and cryogenics. GYLON EPIX® Style 3510 withstands a wide range of chemicals for extended service in a wide variety of applications.