Maintenance Department Manual

ECPL Manufacturing Division

Gasket Selection
& Installation

Document No.
Rev No. / Date
Issue No. / Date
Effective Date
Page No.

MP-WP-21
00 / July 01, 2006
02 / July 01, 2006
July 01, 2006
1 of 8

Originally Prepared by: WA - 2004

PREPARED BY :
Maintenance Engineer / Maintenance Supervisor
(FAISAL IFTIKHAR / KHURSHID M. KHAN)

DATE

Inspection Engineer / Maintenance Section Head

(WAJHAT ABRAR / ABBAS SHAHANI)

DATE

Maintenance Manager
(SYED SHAHZAD NABI)

DATE

REVIEWED BY :

APPROVED BY :

CHANGE RECORD
S#

REV. #

DATE

PAGE #

SECTION

DISTRIBUTION
1. DISTRIBUTION AS PER LIST (MP-100)

Maintenance Department

DESCRIPTION OF CHANGE

Maintenance Department Manual

ECPL Manufacturing Division

Gasket Selection
& Installation

Document No.
Rev No. / Date
Issue No. / Date
Effective Date
Page No.

MP-WP-21
00 / July 01, 2006
02 / July 01, 2006
July 01, 2006
2 of 7

Originally Prepared by: WA - 2004

TABLE OF CONTENTS
1.

2.

INTRODUCTION....................................................................................................................................................... 3
1.1

PURPOSE...................................................................................................................................................... 3

1.2

SCOPE........................................................................................................................................................... 3

1.3

DEFINITIONS / ABBREVIATIONS.................................................................................................................. 3

HEALTH & SAFETY................................................................................................................................................. 3

2.1

PPES............................................................................................................................................................... 3

2.2

HAZARDS....................................................................................................................................................... 3

2.3

GENERAL SAFETY PRECAUTIONS............................................................................................................. 3

2.4

JSA................................................................................................................................................................. 3

2.5

ENVIRONMENTAL IMPACT........................................................................................................................... 3

2.6

SPECIAL INSTRUCTIONS............................................................................................................................. 3

3.

RESPONSIBILITIES................................................................................................................................................. 4

4.

GASKET SELECTION GUIDE LINE......................................................................................................................... 4

4.1

GENERAL PURPOSE GASKETS.................................................................................................................. 4

4.2

SPECIAL SERVICES GASKETS.................................................................................................................... 4

4.3

EXCEPTIONS................................................................................................................................................. 4

5.

GASKET INSTALLATION PROCEDURE................................................................................................................. 5

6.

FINISHING THE JOB................................................................................................................................................ 5

7.

RECORDS................................................................................................................................................................ 6

8.

ATTACHMENTS........................................................................................................................................................ 6

9.

REFERENCES.......................................................................................................................................................... 6

Maintenance Department

Maintenance Department Manual

ECPL Manufacturing Division

1.

Gasket Selection
& Installation

Document No.
Rev No. / Date
Issue No. / Date
Effective Date
Page No.

MP-WP-21
00 / July 01, 2006
02 / July 01, 2006
July 01, 2006
3 of 7

Originally Prepared by: WA - 2004

INTRODUCTION
1.1 PURPOSE
The purpose of this procedure is to provide guide line in the selection & installation of proper
gaskets with respect to service, temperature, pressure and flange rating.

1.2 SCOPE
This procedure only covers the piping gaskets and gaskets for equipments like pressure
vessels, heat exchangers, boiler drums etc. are not in the scope of this procedure. Vendor
supplied asbestos gaskets for aforementioned equipments and for machines are also not in
the scope of this procedure.

1.3 DEFINITIONS / ABBREVIATIONS

2.

1.3.1

AME

AREA MAINTENANCE ENGINEER

1.3.2

AMS

AREA MAINTENANCE SUPERVISOR

1.3.3

MM

MAINTENANCE MANAGER

1.3.4

LFC

LOCAL FABRICATION CELL

1.3.5

ECPL

ENGRO CHEMICALS PAKISTAN LIMITED

HEALTH & SAFETY

2.1

PPEs
2.1.1

2.2

2.3

Ear plug, safety helmet, safety goggle, safety shoes, cotton gloves

HAZARDS
2.2.1

Pinch points.

2.2.2

Leakage of process fluid.

GENERAL SAFETY PRECAUTIONS

2.3.1

2.4

N/A

JSA
2.4.1

2.5

Not required

ENVIRONMENTAL IMPACT
2.5.1

2.6

Improper gasket selection or installation could cause leakage of hazardous gasses or

liquids like ammonia, carbamate, natural gas etc.

SPECIAL INSTRUCTIONS
2.6.1

Always have trained personnel working on the gasket removal & installation.

2.6.2

Ensure that the line is depressurized before starting work.

2.6.3

Ensure that the gasket is as per flange rating.

2.6.4

Always use new gasket in place of old one, after flange opening.

2.6.5

Always use proper tools for the job.

Maintenance Department

Gasket Selection
& Installation

Maintenance Department Manual

ECPL Manufacturing Division

3.

Document No.
Rev No. / Date
Issue No. / Date
Effective Date
Page No.

MP-WP-21
00 / July 01, 2006
02 / July 01, 2006
July 01, 2006
4 of 7

Originally Prepared by: WA - 2004

RESPONSIBILITIES
ECPL technician will be responsible for execution of the job, Supervision of job on part of Area
supervisor / Project Engineer & as an overall to ensure safe execution of job according to defined
ECPL procedures lies with Maintenance / Project section head.

4.

GASKET SELECTION GUIDE LINE

This procedure has two parts:

4.1

GENERAL PURPOSE GASKETS

This includes gaskets being used on general services like steam, condensate, water, air, and
oil etc. For the selection of these gaskets MPR 59/2/00 (Exxons BP chart 3-16-1) to be
referred (see attachment).

4.2

SPECIAL SERVICES GASKETS

This includes gaskets being used on services like Ammonia, Catacarb, Carbamate,
and Urea Solution. For the selection of these gaskets a chart is attached which has
the extracts of all relevant piping specs. The health hazardous and obsolete materials
like asbestos, teflon blue asbestos ring etc have been replaced with appropriate
gasket materials.
Gaskets to be selected as per (MPR 59/2/00 & 02) Table A (BP 3-16-1) & Table B (Special
Services Gaskets) given as attachments in this procedure.
Non asbestos gasket sheet AFM 34 IGV has been stocked in two sizes

4.3

a.

1.5 mm x 1500 mm x 3000 mm

b.

3.0 mm x 1500 mm x 3000 mm

EXCEPTIONS
4.3.1

Exceptions are being given for the use of Asbestos / not recommended Gaskets in
place of standard gaskets where following problems will be faced:
4.3.1.1

Distorted / Uneven flanges

4.3.1.2

Limited gap between flanges

4.3.2

Following steps to be taken before installing Asbestos / Non standard gaskets

4.3.3

Area Engineer / Supervisor will fill the form "Temporary Authorization to install gasket
not conforming BP 3-16-1" (MPR 59/1/00) & will specify the target date of reverting
back to original gasket as per BP 3-16-1.

4.3.4

Area Field Maintenance Unit Manager / Section Head / Section Incharge will review
the request.

4.3.5

Maintenance Manager will approve the temporary authorization form (MPR 59/1/00).

4.3.6

The approved form will be handed over to LFC Engineer along with a work order and
gasket details.

4.3.7

LFC Engineer will assign a Temporary Authorization No. and log it in record file.

Maintenance Department

Maintenance Department Manual

ECPL Manufacturing Division

4.3.8

5.

6.

Gasket Selection
& Installation

Document No.
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Issue No. / Date
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Page No.

MP-WP-21
00 / July 01, 2006
02 / July 01, 2006
July 01, 2006
5 of 7

Originally Prepared by: WA - 2004

Area Engineer / Supervisor to revert to original gasket as per BP 3-16-1 according to

the assigned target date.

GASKET INSTALLATION PROCEDURE

5.1

Select gaskets as per 4.1 & 4.2.

5.2

Ensure the line is depressurized & purged, if applicable.

5.3

Open flange bolts.

5.4

Remove the old gasket & clean the faces of flanges.

5.5

Ensure that flange faces are parallel & holes are aligned. Misalignment should not be tried to
compensate by bolt tightening.

5.6

The mating flange faces must be clean and free from imperfections, like pitting, indentations
and cavities or nicks.

5.7

It is very important that the gasket be properly dimensioned for the flanges in which it is to be
used.

5.8

Install the gasket & ensure that it is properly positioned. Always use new gasket in place of old
one, after flange opening. In extreme conditions if old gasket to be used, it should be reviewed
by Field Maintenance Section Incharge / Section Head / Unit Manager.

5.9

Apply anti seize compound on the bolts.

5.10

Tighten the bolts. The bolts should be tightened first by hand & then tight two bolts 180
degrees apart, advance clockwise 90 degrees and repeat the operation, continue until all the
bolts are stressed equally. This sequence of bolt tightening is known as the "Cross-over"
sequence. For cross-over tightening sequence details, recommended torques and wrench
lengths for the given bolt sizes please see attachment (MPR-WP-21/3/00).

5.11

It is important that the total amount of final stress desired, be applied in small steps.

5.12

Use Torque or Pneumatic wrenches in maintaining equalized bolt stresses, where ever
feasible.

5.13

In case of critical service like ammonia, carbamate, fuel gas etc, supervisor should put
masking tape on flange once the proper gasket is placed and initial on the masking tape
affirming the correct gasket installation.

5.14

Perform leak test & remove leakage, if any.

5.15

For hydrotesting and blinding, temporary gaskets (like used flexitallic on non pressure side
during hydrotesting / non asbestos etc.) to be used.

FINISHING THE JOB

6.1

Return Tools, equipment etc.

6.2

Housekeeping.

6.3

Failure Reporting on CMMS-Maximo (on need basis).

Maintenance Department

Maintenance Department Manual

ECPL Manufacturing Division

7.

8.

9.

Gasket Selection
& Installation

Document No.
Rev No. / Date
Issue No. / Date
Effective Date
Page No.

MP-WP-21
00 / July 01, 2006
02 / July 01, 2006
July 01, 2006
6 of 7

Originally Prepared by: WA - 2004

RECORDS
7.1

MPR-WP-21/1/00 Original with LFC

7.2

MPR-WP-21/1/00 Copy with Unit Manager (FM)

ATTACHMENTS
1.

MPR-WP-21/1/00 Temporary Authorization to Install Gasket Not Conforming BP 3-16-1

2.

MPR-WP-21/2/00 Design Limits for Flange and Gaskets

3.

MPR-WP-21/3/00 Cross-over sequence details for bolt tightening

REFERENCES
1.

Non asbestos gasket manufacturer guide

2.

Exxon BP standards

Maintenance Department