B 15 543

Refinery Based Case Study of a Novel Gasket Designed for Use in

Problematic Shell and Tube Heat Exchangers
B.Sc. Dene Halkyard
Flexitallic Ltd, Cleckheaton, United Kingdom

1 Abstract
This paper provides a technical overview of a novel gasket design engineered to
address sealing issues associated with the operation of shell and tube heat
exchangers. It discusses field service experience using the gasket on a UK refinery.
Shell and tube heat exchangers are commonly used items of process equipment in
many industries. Depending on how they are operated heat exchangers can present
significant technical challenges with regard to achieving leak free sealing
performance. Fluctuations in axial load and radial shear effects brought about by
thermal transients around the tube sheet girth flanges during start up or normal
operation can a have a significant effect on seal performance. Additional factors such
as available gasket load imposed by exchanger design; available space, the
presence of stress raising nubbins and ease of access and installation can also have
a bearing on gasket design.
Refinery processes involving shell and tube heat exchangers can be particularly
demanding, equipment is often old and can involve elevated temperatures, high
pressures and cyclic operation. It is said that every refinery has its problem
exchangers. Additional requirements for improved asset efficiency and emissions
compliance place ever increasing demands on gasket performance.
The novel gasket design offers benefits over traditional gasket styles more
commonly used in shell and tube heat exchanger applications. It offers superior long
term sealing performance, particularly in bolted connections subject to thermal
transients.
Refinery field service discussed in the paper reviews sealing performance in a
number of problematic exchangers at the tube sheet to channel and tube sheet to
shell connections. The heat exchangers, used to process heavy residual

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hydrocarbons are in excess of 30 years old with a history of managed leakage. High
temperature, cyclic operation, seasonal fluctuations in product demand and the
requirement for regular tube cleansing exacerbates the potential for seal failure.
2 Background
As an international manufacturer of industrial seals and gaskets Flexitallic has been
manufacturing and supplying girth, tube-sheet and floating head gaskets for use on
shell and tube heat exchangers for many years. As a consequence Flexitallic
Applications Engineers are familiar with the apparent idiosyncrasies associated with
the sealing performance of individual exchangers. Shell and tube heat exchangers
can come in many designs and is a subject beyond the scope of this paper, however,
they are broadly categorised on the basis of service or construction. See ref. [1] for
additional information on this topic. All shell and tube heat exchangers contain the
following main elements:

Shell
Shell cover
Tubes
Channel
Channel cover
Tube-sheet
Baffles
Nozzles

A schematic of a sectional view of typical shell and tube heat exchanger with a
removable channel cover and stationary tube-sheet, floating head with backing ring
and removable shell cover is shown in figure 1.0. The location of girth, tube-sheet
and floating head gaskets is indicated in red and by the presence of a circled red
number.
Floating head

Shell

Tubes

Shell cover
Figure 1.0: Heat Exchanger Schematic

Channel cover

Nozzle

Baffles

3 2

Tube-sheet

Channel

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Figure 1.0: Heat Exchanger Schematic
Gasket positions indicated by the presence of red circled numbers are generally
named in accordance with the following notation:

Location 1 Channel cover or lid gasket

Location 2 Channel to tube-sheet gasket
Location 3 Shell to tube-sheet gasket
Location 4 Floating head gasket
Location 5 Shell cover gasket

Nozzles are pipe connections that are used to connect the exchanger to process
piping consequently they utilise standard flanges and gaskets such as those defined
in ASME B16.5 and ASME B16.20 respectively. However girth i.e. channel cover,
tube-sheet, shell cover and floating head connections are usually dimensionally
bespoke and gaskets are designed accordingly. Flange face configuration of
bespoke connections is generally recess to spigot (male to female) in line with TEMA
guidelines (see ref. [1]). In spigot to recess face configurations the gasket, when insitu, is confined on the outer diameter. This kind of arrangement can give rise to
gasket width limitations particularly on floating head connections that can have an
impact on gasket selection.
For multi-pass exchangers the direction or channelling of process fluid is controlled
by the use of partition plates on the tube side of the exchanger. This necessitates the
use of gaskets with the incorporation of pass bars. The number and location of pass
bars is dictated by the direction and complexity of the process flow on the tube side
of the exchanger. The pressure differential across the pass bars is usually
significantly lower than that between the shell and tube side of the exchanger or
between process media and the atmosphere. Depending of gasket style pass bars
can be integrated i.e. part of the primary seal, or fixed in position by welding.
An area of particular interest is the gasketed connections located across the tubesheet. The tube-sheet is the barrier that separates the two process fluids i.e. the
shell and the tube fluids, between which heat transfer takes place. As a
consequence gaskets at these locations can be, depending on operational
conditions, subject to changes in both axial and radial load. In a fixed tube-sheet
arrangement, as shown in figure 1, there is a gasket located on both the shell and
channel side of the tube-sheet. In such cases it is generally recommended to use the
same gasket style in both locations. It is regular practice to use common bolting
across the tube-sheet to effect compression of both the shell to tube-sheet and
channel to tube-sheet gaskets. A schematic of this arrangement is shown in figure 2.

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Bolting
Shell flange

Channel flange

Channel/tubesheet gasket

Shell/tubesheet gasket
Tube sheet
Figure 2: Tube-sheet - Bolting and Gasket Arrangement
3 Current Gasket Technology

Various styles of gasket are used in shell and tube heat exchangers. The following
short overview represents the most commonly used styles encountered in the Oil
and Gas industry.
3.1 Metal Jacket Gaskets
The traditional gasket style used for the sealing of non-standard heat exchanger
connections in the Oil and Gas Industry has for many years been based around
metal jacketed technology. Metal jacketed gaskets, as the name implies, are
comprised of a thin metal jacket, typically 0.4mm formed around a soft compressible
core. Common jacket materials include soft iron, carbon and austenitic stainless
steels in combination with core materials such as graphite foil, millboards and fibre
reinforced sheet gasket materials. Figure 3 shows a typical section through a double
metal jacketed gasket.
Lid

Metal jacket

Core
Box
Figure 3: Double Metal Jacketed Gasket - Section

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Other metal jacketed styles are sometimes used incorporating surface corrugations,
internal metal components or of single jacket construction. Metal jacketed gaskets
have several inherent weaknesses with regard to creating and maintaining a seal
namely; they require a relatively high unit stress to form a seal because of the
requirement for metal deformation (stress raising nubbins are sometimes used to
mitigate this). Successful metal to metal sealing also requires relatively smooth and
blemish free flange sealing faces, this can be particularly problematic on older
equipment. They possess very poor recovery characteristics; as a consequence
sealing performance under load fluctuations can be compromised. Resistance to
radial shear effects has been shown to be poor under RAdial Shear Tightness
(RAST) testing.
3.2 Corrugated Metal Gasket
Corrugated metal gaskets (CMG) are also used in used in heat exchanger
applications. They are comprised of a relatively thin metal, typically 0.4 mm thick,
core that has been concentrically corrugated and faced with a soft facing material.
Corrugation pitch and height can vary depending on the manufacturer and gasket
geometry. A typical material combination would be austenitic stainless steel in
combination with a graphite based facing material. See figure. 4.
Facing material

Metal core
Figure 4: Corrugated Metal Gasket Section
This style of gasket offers some benefit over double jacket gaskets with regard to
reduced seating stress and flange surface requirements. It is generally not suitable
for use in narrow land width sealing applications and may not be suitable for cyclic
service because of resilience limitations.
3.3 Spiral Wound Gaskets
Spiral wound gaskets (SWG) have been used in heat exchanger service for many
years and special TEMA type designs have been developed to assist in gasket
Installation. SWG are manufactured by spirally winding alternative wraps of a thin
strip of a metal (wire) and non-metallic sealing material (filler) around a mandrel. The
strips are formed into a chevron profile during the winding process, resistance spot
welding the wire at the start and termination of the winding process results in a

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sealing element. Gasket resilience and stiffness can be altered to suit the specific
application. Handling and installation of larger gaskets can present difficulties and
care may need to be exercised to prevent the gasket from springing if twisted or
mishandled. Over compression of the sealing element is normally prevented by the
incorporation of a solid metallic inner compression ring of predefined thickness. The
requirement for compression control can limit the use of SWG, especially in
applications where space is limited, such as floating head connections. Typical
materials of construction used in hydrocarbon service are graphite in combination
with austenitic stainless steel. SWG offer significant advantages over metal jacketed
gaskets in several key areas. Namely, lower seating stress requirements, improved
resistance to radial shear effects and an increased tolerance to sealing face surface
finish. Figure 5 shows a section through a spiral wound gasket modified for heat
exchanger service.
Inner compression ring

Sealing element

Outer location nose

Figure 5: Spiral Wound Gasket - Section

3.4 Kammprofile Gaskets
Kammprofile gaskets are comprised of a serrated solid metal core with soft nonmetallic facing material bonded to each face. Serration profile, facing material
thickness and density should be carefully controlled as it can have a bearing on
sealing performance. As with SWG, for hydrocarbon service typical materials of
construction are stainless steel and flexible graphite. Benefits offered over other
gasket styles are low stress sealing, their ability to accommodate flange face defects,
use of narrow sealing widths, high load bearing capability and ease of handling and
installation - even for very large gaskets. A typical schematic of a sectioned
kammprofile gasket is shown in figure 6.
Metal core

Facing material
Serrations
Figure 6: Kammprofile Gasket - Section

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4 Novel Gasket Design

4.1 Design and Construction
Over many years of field service experience the shortcomings of traditional gasket
styles in problematic heat exchanger applications is well known to Flexitallic
engineers. With the objective to address such issues, extensive research and
development work was undertaken that resulted in the production of a novel gasket,
herein known as the Change gasket. The Change gasket has been designed to
possess the optimum combination of both stiffness and resilience and as a
consequence be capable of effecting a high performance seal under conditions of
long term cyclic service; such as those routinely encountered in demanding shell and
tube heat exchanger sealing applications.
The preferred manufacturing approach involved producing a gasket from a wire strip;
thus offering both maximum manufacturing flexibility and cost savings with regard to
material utilisation. The strip is spirally wound however, the strip profile and thickness
differs significantly from that used in the manufacture of SWG. See figure 7. The wire
strip used in the manufacture of the Change gasket approximately 5 times thicker
than that used in the production of SWG. As a consequence significant modification
was required to standard SWG production machinery to enable manufacture.

Change

Spiral Wound

Figure 7: Gasket Wire Profiles

Upon winding, the unique profile and increased thickness of the wire results in a stiff
yet resilient interlocked structure with greatly improved handling characteristics
compared to that of standard SWG. The resulting stiffer construction can in many
instances negate the requirement to control gasket compression allowing its use in
applications where space may be limited. A soft filler material, such as graphite, is
incorporated into the gasket during the winding process. Once wound the resulting
profile of the gasket sealing faces bears resemblance to that of a kammprofile
gasket. Both sealing faces may be subsequently covered with a layer of soft facing
material, providing low stress sealing and good conformance on poor flange faces. A
schematic of a sectioned profile of the gasket in given in figure 8.

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Facing material

Metallic winding strip

Serrations

Figure 8: Change Gasket - Section

One of the main operational challenges in manufacturing the gasket was how to
permanently fix the winding strip at the start and termination of the winding process.
Conventional resistance spot welding could not be used because of the increased
wire thickness. Weld integrity in an unconfined spiral wound seal arrangement such
as this plays a crucial role in maintaining seal integrity. To this end various welding
techniques were investigated. Following extensive trials, high power, precision laser
welding was selected. Laser welding involves creating a localised, high precision,
deeply penetrating high energy plasma reducing. Due to the localised nature of the
technique thermal stresses are kept to a minimum resulting in a reduced heat
affected zone compared with traditional welding methods. No additional welding
material is involved, the result is a high strength weld capable of maintaining gasket
integrity when exposed to fluctuating high load. See figure 9 for weld detail.
Section View

Plan View

Figure 9: Change Gasket Weld Detail

4.2 Laboratory Testing
During the development programme the Change gasket was subjected to the usual
battery of both standard and non-standard laboratory testing. ASME VIII (ref.[2],
PVRC ROTT (ref. [3]) and EN13555 (ref. [4]) testing was undertaken to assess
sealing behaviour under assembly and dynamic loading conditions and to generate
the relevant gasket constants. However, to assess long term multi-cyclic load

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conditions and attempt to accurately simulate shell and tube heat exchanger
conditions, particularly at the tube sheet gasket positions, testing was undertaken
using a modified extended version of the Shell Thermal Cycle test. This test is part of
the Shell Type Approval Testing requirement for semi-metallic gaskets. In addition to
testing the Change gasket benchmark testing was also undertaken on all the
previously reviewed gasket styles.
4.2.1 Extended Shell Thermal Cycle Testing
The Shell thermal cycle test involves subjecting a standard gasketed bolted
connection to a series of thermal cycles. Leakage performance is determined by a
series of pressure decay tests carried out at defined stages during the test.
The test rig consists of a pair of ASME B16.5 NB 4raised face flanges incorporated
into a welded pressure vessel that is fitted with an internal heating element. The test
gasket is stressed via hydraulic tensioning of eight ASTM A193 B16 stud bolts. The
induced bolt stress is 290 N/mm2. The test medium is nitrogen. A schematic of the
test rig is given in figure 10.
The test regime was as follows:
a) Assemble and pressurise the test rig to 51 bar
b) Undertake room temperature pressure decay test over 1 hour
c) Depressurise and heat up the test rig to 320oC at 2oC/min.
d) Re-pressurise to 33 bar followed by pressure decay test over 1 hour
e) Allow to cool
In the standard test parts c) through e) are repeated a total of 3 times. Test pass or
fail is determined by pressure testing; the maximum allowable pressure drop either
prior to and/or after the final thermal cycle is 1 bar (14.5 psi) over a one hour period.
Leakage rates higher than this result in test failure. Each thermal cycle takes
approximately 24 hours to complete. Extended benchmark testing of the all the
gasket styles involved increasing the number of thermal cycles from three to twenty
four or until test failure. The number of cycles and test temperature was selected
after consultation with industry engineers; it being regarded as being representative
of a typical process temperature and number of process trips, or thermal excursions
an exchanger may be subjected to between scheduled maintenance outages.
Graphical test results are shown in figure 11. Under standard Shell test conditions
i.e. three thermal cycles, all gasket styles are compliant. However test modification to
increase the number of thermal cycles highlighted some significant differences in
sealing performance.

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Pressure gauge

To vent/gas supply
Pressure isolation valve

Test gasket

Thermal insulation
Heating element
Figure 10: Shell Test Rig Schematic
4.2.2 Extended Thermal Shell Cycling - Test Results
With the exception of the corrugated metal gasket and the Change gasket all other
gasket styles; kammprofile, double jacketed gasket and SWG gave similar levels of
performance, all failing to meet or exceed the maximum allowable pressure drop
requirement of 1 bar/hour after exposure to between 14 to 16 thermal cycles. The
corrugated metal style gasket performed the worst failing pressure test after 5
thermal cycles.
It can be seen from the data that the Change gasket significantly out performed all
other gasket styles and was the only gasket able to meet the requirements of the
test. After the completion of all 24 cycles the measured pressure drop was 0.07 bar
(1 psi). The test was subsequently repeated and the results proved to be consistent.
The test data clearly demonstrates that, under the described test regime, the Change
gasket offers significantly improved sealing performance under thermal cycling
conditions compared to traditional gasket styles.

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Figure 11: Pressure v Thermal Cycle Number

Legend:
DJ = Double jacketed gasket
CMG = Corrugated metal gasket
CGI = Spiral wound gasket
Kamm = Kammprofile gasket
Change = Change gasket
Red broken line (
) = Failure point (1 bar/hr pressure drop)
4.2.3 Radial Shear Testing
An important consideration when designing a gasket for heat exchanger applications
is the possibly of the gasket being exposed to radial shear. This can occur due to
differences in radial expansion when the tube sheet is exposed to a thermal gradient
resulting from different temperatures on the shell and tube-side of the exchanger.
Radial shear can result in gasket damage and seal failure. Work carried out in the
past has shown that certain gasket styles are superior to others at resisting radial
shear. See ref [5].
A test protocol has been developed by Yarmouth Research in the US, see ref. [6].
The test involves exposing a gasket located in a tongue and groove flange
arrangement to a thermal differential induced by heating one of the flanges to 300oC
while cooling the other using water. The minimum amount of radial shear the test
gasket is exposed to during the test is 0.51 mm. The test is comprised of exposing a

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test gasket to 20, 40, 60, 80 and a 100 thermal cycles. Following each radial shear
test the assembly is pressure tested at room temperature with nitrogen at 40 bar on
an hourly basis over the next 4 hours. In addition to leakage performance bolt
relaxation is recorded at the start and finish of each test. This is an important
indicator of seal performance as loss of strain energy in the connection is primary
reason for seal failure. SWG have been shown to perform well in radial shear testing
and they typically give rise to an average bolt relaxation value in the order of 25%.
Average bolt relaxation as measured for the Change gasket was 15% with no
significant leakage observed, see ref. [6].
4.2.4 Sealing on Nubbins
Depending on the age and original gasket style designed for the heat exchanger it is
not uncommon to for girth flanges to have stress raising nubbins incorporated into
the bottom of the recess of the mating flange. See figure 12. The primary objective is
to raise the unit stress on the gasket thus improving sealing efficiency on assembly.
Nubbins raised sections in the bottom of the flange, are generally used in
connections where solid metal or double jacketed gaskets are used. Their presence
can preclude the use of SWG and kammprofile sealing technology as they can result
in gasket damage that can compromise seal integrity. As a consequence nubbin
removal is normally recommended when using SWG or kammprofile gaskets, adding
additional cost and time to maintenance programmes.
Spigot flange
Gasket

Recessed flange
Nubbin
Figure 12: Flange and Gasket Arrangement with Nubbin - Section
Sealing performance of the Change gasket has been assessed in a flanged
connection with nubbins present. A specially developed test fixture was used in
which a 0.4mm x 3mm (high x wide) nubbin was machined. A test gasket was
installed and the test fixture pressurised using nitrogen gas, across a range
pressures from 17 to 103 bar (250 to 1500 psi). The test pressure was held for 5
minutes during which the test rig was submerged in water and subjected to a bubble
test. Leakage performance at two gasket stresses was investigated. The tabulated
test data is shown in table 1. Post test visual inspection of the sectioned gasket was
carried to assess gasket damage. The gasket remained intact with only minor

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deformation. Several Change gaskets have now been successfully used in

connections in which stress raising nubbins are present.
Table 1: Change Gasket Leakage Performance with Nubbins
Internal Pressure N2(bar)

Leak rate (bubbles/min)@

Gasket stress 103 N/mm2

Leak rate (bubbles/min)@

Gasket stress 206 N/mm2

17.2

34.5

51.7

68.8

86.0

103.4

5 Field Service
Since the development and introduction of the Change gasket many have been
supplied and are currently being used in non-standard connections in shell and tube
heat exchangers around the world.
The following is an account of the Change gasket being used in a problematic
application at Totals Lindsey Oil Refinery (LOR) located at Immingham in the UK.
5.1 Background
Flexitallic Application Engineers were consulted following repeated leakage issues
on two banks of shell and tube heat exchangers on the visbreaker unit. The
visbreaking process is designed to reduce the viscosity and pour point of the heavier
hydrocarbon fractions resulting from vacuum distillation (VD) of crude oil.
Visbreaking is one of several cracking processes used on modern complex oil
refineries, see ref. [6]. The commercial success of any refining operation depends to
a great extent on the ability of the refinery to process a range of crude oil qualities
and ensure optimum product yield is aligned with market demand. This generally
means having the flexibility to convert higher molecular weight hydrocarbon fractions
to lower weight fractions with the correct molecular structure. Visbreaking is a
relatively mild thermal cracking procedure compared to other commonly used
processes. Mild refers to the extent of the cracking reaction rather than the absolute
temperatures at which it takes place. The extent of the reaction is controlled by

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quenching the products immediately after leaving the reactor. Two technologies are
commonly employed, furnace (or coil) and soaker (or drum) processes. In the former
the visbreaking reaction takes place directly in the furnace coils while in the latter it
occurs away from the furnace in a specially designed unit known as a soaker.
Soaker units operate at relatively low temperatures and use longer residence times
compared with coil units. A simplified schematic of the soaker visbreaking process is
shown in figure 13. The main benefits of the soaker process are reduced energy
requirements and increased run times because of reduced reactor coking rates
however, the decoking process itself can be more complex due to soaker design.
Coking, or fouling, is an important consideration in refinery processes as it can have
a significant impact on plant efficiency. Carbon deposits have a negative effect on
both heat transfer efficiency and feedstock and product throughput.

Figure 13: Soaker Visbreaking Process - Simplified Schematic

5.2 Application Details
The visbreaking operation used on the refinery is based on soaker technology. Prior
to visbreaking the virgin feedstock (VD residues) is pre-heated via a bank of four
shell and tube heat exchangers. The exchangers were commissioned around 33
years ago and have history of managed leakage. Over the years the girth flanges
have been re-machined to rectify flange distortion and corrosion issues and remain
within corrosion allowance limits. Mechanical clamps and injectable sealants have
been employed on a temporary basis on a number of occasions to mitigate leakage
at the tube-sheet connections and allow continued running of the visbreaker unit in
between planned shutdown programmes. Several different gasket styles have been
previously evaluated with some noted differences in performance, however, none
have given the required level of service.

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The exchangers have been designed to ASME VIII Div. 1 TEMA R pressure vessel
code and categorised as TEMA Class AES. The flanges do not contain stress raising
nubbins. Test, design and operating conditions are given in table 2.

Table 2: Test, Design and Operating Conditions

Shell Side

Tube Side

Design Pressure (barg)

38

36

Test Pressure (barg)

57

56

Design Temperature (oC)

370

390

Op. Temp Outlet (oC)

335

283

Op. Temp Inlet (oC)

192

365

Media

VD Residue

Visbreaker Residue

As is common, for reasons of economy visbreaker residue is used as the heating

medium on the tube-side of the exchanger. The negative impact of this is regular
coking or fouling of the internals of the exchanger bundle.
Two banks of exchangers are used to pre-heat feedstock, however only one bank is
in operation at any one time. This allows routine maintenance to be carried out
without shutting down the visbreaker unit. Each bank of 4 heat exchangers consists
of 2 x 2 vertically aligned units designated 91E1 - A, B, E, F and 91E1 - C, D, G, H.
Each of the two banks is connected in series. Photographs of the units in operation
are given in figure 14.

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Figure 14 Visbreaker Preheater Shell and Tube Heat Exchangers

Because of the nature of the feedstock and pre-heat medium (visbreaker residues)
fouling or coking of the exchangers, particularly on the tube side is commonplace.
For operational efficiency reasons cleaning or de-coking is undertaken on a regular
basis. Cleaning requires taking the units off line. The cleaning regime employed
depends on the extent and location of coking. If coking is limited to the tube-side of
the exchanger cleaning involves removal of the channel cover and reverse jet
cleaning the tube bundle using ultra-high pressure water. In this instance the tube
sheet gaskets are not removed and remain under compressive load. However the
act of taking the unit off line subjects the tube sheet gaskets to significant thermal
shock. Subsequently some time in the future; typically after a 2 to 3 month period the
tube sheet gaskets are subject to additional thermal shock when bringing the unit
back on line and up to operational temperature. Coking on the shell side of the
exchanger is less problematic and requires less frequent attention however, shell
side cleaning requires the removal of the shell cover i.e. the tube bundle is fully
removed, and removal of the floating head to allow full through jet cleaning. In this
case the connection across the tube-sheet is broken and new gaskets installed on
re-assembly of the exchanger. The frequency of cleaning (de-coking) is primarily
determined by the nature of the VD feedstock (crude) and process conditions. Over
the last few years and increasingly as we go into the future the ability of a refinery to
process a wide range of heavier and dirtier crude feed stocks is a key factor to
economic success. However as can be seen in this example it can place increasing
demands on gasketed flanged connections.
Changes in product demand patterns have also, over the last few years exacerbated
sealing issues on the pre-heater exchangers. The need for bitumen a key raw
material used in the production of road surfaces has increased and, as consequence
has become an economically viable refinery product. This has had a direct impact on

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the production of visbroken distillates as VD heavies are an important source of

bitumen. The demand pattern for bitumen is seasonal and summer months in Europe
generally gives rise to an increase in demand, providing economic incentive to
maximise the production of VD heavies. At such times the visbreaker unit is in put
into bypass mode reducing the inlet and outlet temperatures on both the shell and
tube side of the exchanger in the order of 100oC. The frequency of placing the
visbreaker unit to bypass mode depends on product demand patterns. Typically the
exchangers are in bypass mode 12 days per calendar month during summer. This of
course leads to additional non-cleaning related thermal transients resulting in
additional stress fluctuations across the tube-sheet connection.
It estimated that the average number of thermal cycles the exchangers are exposed
to because of cleaning and/or standby mode operation is two per month.

5.3 Gasket Selection

Over recent years many different gasket styles have been evaluated. Originally the
exchangers were supplied with double metal jacketed gaskets. Following leakage
issues spiral wound gaskets were installed and more recently kammprofile gaskets
have been used. Both spiral wound and kammprofile gaskets proved to offer
advantages over jacketed gaskets however all gasket styles failed with regard to
providing long term i.e. greater than shell side cleaning interval requirements, leak
free performance at the tube sheet gasket locations.
In light of gasket history and operational considerations Change gaskets were
designed for both the channel/tube sheet and shell/tube sheet locations. Because of
the relatively large size of the connection, in excess of 1.5 m diameter and the
available space both gaskets were fitted with solid inner rings. The channel tube
sheet gasket was fabricated with internally welded double jacketed pass bars. See
figure 15 for gasket details.

Figure 15: Change Gasket Channel

to Tube Sheet

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Gasket materials of construction were as follows:

Winding, inner ring and jacket material: UNS31603 (SS316L, WN1.4404)
Filler and facing material: High purity graphite (Flexicarb HT)
Bolting and tightness calculations were carried out in accordance with ASME VIII
Appendix II and PVRC Convenient method (Draft). ASME VIII appendix II
calculations indicated code compliance with operational conditions requiring a bolt
area of 47076 mm2 (Am1) with a corresponding available bolt area (Ab) of 54387
mm2. PVRC Convenient calculations indicated a T3 tightness class at a residual bolt
stress of 210 MPa (30.5 ksi) with an equivalent gasket stress of 110 MPa (15.9 ksi).
The gaskets were installed using best practice assembly techniques. Hydraulic
torque was used to induce bolt stress during flange assembly. Target bolt stress on
installation was 310 MPa (45 ksi) with an equivalent assembly gasket stress of 162
MPa (23.5 ksi). Flange calculations were carried out to ensure flange stresses and
bending moments were kept within acceptable ASME/Taylor Forge design limits.
5.4 Sealing Performance
At the writing of this paper the Change gaskets were installed 14 months ago (May
2013) on units 91-E1 A, B, E and F and 8 months ago (October 2013) on exchangers
91-E1 C, D, G and H. Throughout these periods the visbreaker preheaters have
been in constant use; processing visbreaker feed stock or in standby mode,
depending on product demand profile. Since installation there has been no
requirement to undertake shell side cleaning so the tube-sheet connection has not
been opened and the gaskets have not been replaced. However, tube side cleaning
has been carried out on a number of occasions. The total number of thermal cycles
to which the tube-sheet connection has been subjected is in the order of 28 for units
A through D and 16 for units F through G. Regular visual monitoring of the
connections has shown no incidence of leakage across any of the 16, previously
problematic tube-sheet connections. Discussions with plant engineering personnel
suggest that if using conventional gasket technology that an incidence of leakage
would have been extremely likely over this time period and that the adoption of
Change gasket technology represents a significant improvement in the maintenance
of joint integrity on these problematic units.

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6 Conclusions
Under the refinery field conditions described the Change gasket offers a significant
advantage over traditional gasket designs namely; SWG, jacketed and kammprofile
gaskets, in heat exchanger tube-sheet connections subject to thermal transients.
Under the laboratory test conditions described the Change gasket is able to
accommodate fluctuations in both axial and radial load to a much greater degree,
maintaining a high integrity seal when benchmark tested against other gasket styles.
The Change gasket represents a fundamentally new design concept offering the
optimum balance of resilience; usually associated with spiral wound gaskets and
stiffness; usually associated with kammprofile gaskets, over the typical stress
range(s) generated in bolted connections.
7 References
[1]

Standards of the Tubular Exchanger Manufacturers Association (TEMA) 9th

Edition (2007).

[2]

ASME VIII Div 1 (2010) Appendix II Rules for bolted flanged connections with
ring type gaskets

[3]

PVRC ROTT Draft 10.01 Standard test method for gaskets constants for
bolted joint design (April 2001)

[4]

BS EN13555 2014 Flanges and their Joints. Gasket Parameters and test
procedures relevant to the design rules for gasketed circular flange
connections.

[5]

Heat exchanger gaskets radial shear testing. Viega, Kavanagh and Reeves.
PVP2008-61121

[6]

Yarmouth Research and Technology. Report/Project No. 2120450 2013

[7]

William L Leffler. Petroleum Refining in Nontechnical Language 4th Edition

(2008).

[8]

Russ Currie Change Gasket Overview and Recent Developments

PVP2013-97050 ASME Pressure Vessels and Piping Conference. Paris 2013

8 Acknowledgements
I would like to express my special thanks to Mr Kevin Wallace, plant engineer on
Totals Lindsey Oil Refinery for his support in producing this paper.