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Technical report Gaskets for polyethylene (PE) pipe connections
A technical paper presented by
James Walker Australia Pty Ltd
Abstract: A technical guide for gaskets to suit PE pipe connections
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.
Gaskets for PE pipe connections
Table of Contents
1.0 REFERENCES AND STANDARDS ................................................................................................ 2
2.0 PURPOSE ....................................................................................................................................... 3
3.0 INTRODUCTION ............................................................................................................................. 3
4.0 SCOPE ............................................................................................................................................ 3
5.0 PE PIPE CLASSIFICATIONS ......................................................................................................... 4
6.0 PE FLANGE CONNECTIONS ......................................................................................................... 4
7.0 METAL BACKING RINGS ............................................................................................................... 5
8.0 GASKET TYPES, STYLES ............................................................................................................. 7
9.0 GASKET MATERIAL SELECTION ................................................................................................. 8
10.0 GASKET DIMENSIONS .................................................................................................................. 9
10.1 Gasket inside diameter ..................................................................................................... 10 10.2 Gasket thickness .............................................................................................................. 11
11.0 BOLT LOAD/TORQUE VALUES ................................................................................................... 11
12.0 HOW TO ORDER GASKETS ........................................................................................................ 13
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
Technical report – Gaskets for PE pipe connections v3(Released)
James Walker TR14-08 – v3(Released) Page 2 of 14 Updated: 03-MAR-2015
Document Control
Rev Revision date
Summary of Changes Changes marked
0.1 14-AUG-14 Initial draft
0.2 18-AUG-14 Updated after internal review by JWA
1.0 01-SEP-14 Released following general technical review. References to ePTFE material removed. Material selection for potable water updated
2.0 10-FEB-15 Revised per comments received from PL&PS review team.
3.0 03-MAR-15 Added notes to disadvantages for drop-in gaskets (Fig 5 and Table 6)
Glossary A list of terms, abbreviations and acronyms used within the document.
Abbreviation Definition
ESA European Sealing Association
FSA Fluid Sealing Association
HDPE High density Polyethylene
PE Polyethylene
1.0 References and Standards
The following related documents and standards are referenced in this document.
Reference document Title Issue Date(3)
POP007(1) METAL BACKING FLANGES FOR USE WITH POLYETHYLENE (PE) PIPE FLANGE ADAPTORS
01-MAR-2006
TN-38(2) Bolt Torque For Polyethylene Flanged Joints JULY-2011
AS/NZS 4130 Polyethylene (PE) pipes for pressure applications 2009
AS ISO 9624 Polyethylene (PE) pipe for fluids under pressure – mating dimensions of flange adaptors and loose backing flanges
2008
ASME B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard
2013
ASME B16.21 Non-metallic flat gaskets for pipe flanges 2011
ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly
2013
AS/NZS 2129 Flanges for pipes, valves and fittings 2000
AS/NZS 4331 (ISO 7005)
Metallic flanges – steel flanges 1995
AS/NZS 4087 Metallic flanges for waterworks purposes 2011
AS/NZS 4020 Testing of products in contact with drinking water 2005
AS/NZS 4623 Jointing compounds and materials for use in gas pipe joints
2008
ISO 7483 Dimensions of gaskets for use with flanges to ISO 7005 1991
Technical report – Gaskets for PE pipe connections v3(Released)
James Walker TR14-08 – v3(Released) Page 3 of 14 Updated: 03-MAR-2015
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.
Technical report – Gaskets for PE pipe connections v3(Released)
James Walker TR14-08 – v3(Released) Page 4 of 14 Updated: 03-MAR-2015
5.0 PE Pipe classifications
HDPE piping is available in various pressure categories and wall thickness.
The most common standard in use in Australia is AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure applications. There are two basic categories of pipe in this standard; PE80 and PE100. These are actually different compounds.
The pipe is classified by an SDR rating. This is the Standard Dimension Ratio of pipe DN to pipe wall thickness. The relationship between the dimensions of the pipes, the PE material classification and the working pressure rating are shown in table 1. For simplicity, the dimensions of the pipe have been referred to in terms of the Standard Dimension Ratio (SDR) where: SDR = (Outside Diameter) / (Wall Thickness).
Table 1-Comparison of SDR and Pressure ratings (PN)
SDR 41 33 26 21 17 13.6 11 9 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.
The gasket with a reduced ID and thus increased stress area is recommended where low stress gasket materials such as elastomeric are used.
Technical report – Gaskets for PE pipe connections v3(Released)
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Figure 2- PE stub flange to Metal flange
Fig-2 shows a typical PE stub flange to Metal flange arrangement where the stub flange is secured with a metallic backing ring having the same standard dimensions as the metal flange.
Note the difference between the pipe bore of the metal and PE pipe. This needs to be considered when selecting gaskets for this style of connection.
The ASME B16.21 dimensioned gasket and similar would be appropriate when high compressive strength materials such as CNAF are used for gaskets.
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 Metal backing rings
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 Companion gasket standard
ASME B16.5 Class 150 ASME B16.21
AS/NZS 2129 Table D None
AS/NZS 2129 Table E None
ISO 7005-1 (AS/NZS 4331-1) Table 10 or PN10 ISO 7483
ISO 7005-1 (AS/NZS 4331-1) Table 11 or PN16 ISO 7483
AS/NZS 4087 Fig B7 and PN16 AS/NZS 1646 – material only
AS/NZS 4087 Fig-B8 and PN21 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.
Technical report – Gaskets for PE pipe connections v3(Released)
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Table 3- Pipe DN to Backing ring/Flange/gasket DN per POP007
Pipe DN (Nom pipe OD)
Backing ring or flange DN (Gasket DN)
Backing ring/flange NPS (Gasket NPS)
AS
ME
B16
.5
AS
/NS
Z 2
129
ISO
700
5
AS
/NZ
S 4
087
mm mm inch
20 15 ½
25 20 ¾
32 25 1
40 32 1 ¼
50 40 1 ½
63 50 2
75 65 2 ½
90 80 3
110 100 4
125 100
125 125 5
140 125 5
160 150 6
180 150 6
200 200 8
225 200 8
225 225
250 250 10
280 250 10
315 300 12
355 350 14
400 400 16
450 450 18
450 500
500 500 20
560 550
560 600
630 600 24
710 700
800 800
Technical report – Gaskets for PE pipe connections v3(Released)
James Walker TR14-08 – v3(Released) Page 7 of 14 Updated: 03-MAR-2015
Pipe DN (Nom pipe OD)
Backing ring or flange DN (Gasket DN)
Backing ring/flange NPS (Gasket NPS)
AS
ME
B16
.5
AS
/NS
Z 2
129
ISO
700
5
AS
/NZ
S 4
087
mm mm inch
900 900
1000 1000
8.0 Gasket types, styles
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.
Fig -3 Ring gasket style
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.
Table 4 - Ring gasket summary
Advantages Disadvantages
Very economical Risk of misalignment is high
The same gasket may fit multiple connection classes since the OD and bolt holes do not need to be matched.
Fitting process can be more difficult
Fig -4 Full face gasket style
This is the most common gasket style employed and is recommended for all applications.
Technical report – Gaskets for PE pipe connections v3(Released)
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Table 5-Full face gasket summary
Advantages Disadvantages
Easy to fit More expensive than ring style
Self-centrering Not interchangeable between different backing ring standards.
Fig -5 Drop-in gasket style
This is not in common use but is available as an alternative to full face gaskets.
Not generally recommended.
Table 6-Drop-in gasket summary
Advantages Disadvantages
Easy to fit – only need to align two studbolts.
More expensive than ring style
Self-centrering Not interchangeable between different backing ring standards.
Bolt loads may not be evenly distributed.
9.0 Gasket material selection
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.
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Table 7 - Gasket material selections
Details Units Elastomers (1) CNAF
Material type Nitrile Neoprene EPDM Sentinel INCA
Max operating pressure (4) bar (MPa)
8 (0.8) 8 (0.8) 8 (0.8) 100 (10) 100 (10)
Max operating temp Deg C 100 110 120 400 350
Minimum gasket operating stress
MPa 2 2 2 15 15
Maximum gasket initial stress MPa 10 10 10 50 50
Suitable for Gas (2)
Suitable for water, waste water
Recommended for Potable water (3)
(3) (3) (3)
1) Applies to reinforced and non‐reinforced good quality elastomeric sheet material but NOT specialised
gaskets with metal inserts or other unique designs. These designs may well be suitable for higher pressures
and different operating stresses.
2) Sentinel has AGA Gas approval to AS/NZS 4623 Class 3 up to 2,000 kPa
3) Potable water applications may require special grades of EPDM and may require approval to AS/NZS 4020
requirements in Australia. Details are available on request. Both Sentinel and INCA also have WRAS UK
approval for hot/cold water up to 85 deg C.
4) Operating pressures for CNAF can vary by thickness. Max values shown for info only and substantially
exceed PE pipe ratings anyway.
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.
Technical report – Gaskets for PE pipe connections v3(Released)
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Table 8 - How to determine dimensional properties of gaskets
Feature Gasket style Criteria for dimensions Notes
Gasket OD Ring style Calculate Backing ring PCD minus 1 Bolt hole diameter
Full face, drop-in
Use OD of backing ring as per standard of metal backing ring selected
Same as backing ring OD
No of holes Full face, drop-in
Refer to flange standard applicable to backing ring
Same as backing ring
Hole dia. Full face, drop-in
Refer to flange standard applicable to backing ring
Same as backing ring
Gasket ID ALL styles Refer to guidelines shown at para 10.1 and table 9 below
Gasket thickness
ALL styles Refer to guidelines under heading “Gasket thickness”
10.1 Gasket inside diameter
This is a key requirement which needs to be considered along with the material selection.
In general, for elastomeric gasket materials, make the gasket ID closer to the pipe bore to maximise the stress area available. Conversely with high compressive strength materials such as CNAF it is important to ensure the stress area is not too high. Gasket IDs in line with ASME B16.21 are recommended for such materials.
We could attempt to establish a series of complex tables to list every gasket ID after considering each pipe/flange SDR, DN, stub flange OD and various gasket materials etc. Instead, we will present a set of relatively simple rules from which may be derived the suggested gasket ID.
Virtually all existing National and International gasket standards establish the gasket’s ID based on the nominal metal pipe OD. This is indeed the basis for ASME B16.21 etc.
Table 9 provides recommended practices when determining the gasket inside diameter.
Table 9-How to determine correct gasket ID
Gasket material Max operating pressure – bar
(MPa)
PE to PE connection
PE to metal flange connection
Elastomeric (1) 8 (0.8) Use Rule #1 Do not use
CNAF materials 100 (10) (2) Use Rule #2 Use Rule #2
1. As shown in table 7, applies to good quality, standard reinforced or non‐reinforced sheet material only.
2. These values exceed maximum rating of PE pipe and are shown for information only.
3.
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10.1.1 Rule #1 definition
Define gasket ID based on mean pipe diameter for stated pipe DN and SDR rating per AS 4130.
Recommended for elastomeric materials. This approach maximises the available gasket stress area so that reasonable bolt loads may be achieved.
Not recommended for high compressive strength materials such as CNAF materials because the available flange bolt loads may be far too low to deliver the required minimum gasket operating stress with resultant joint failure or leakage, especially when factoring in the reduced maximum permissible flange stresses and recommended bolt loads for PE flanges. This is a typical cause of poor joint integrity and is often incorrectly attributed to the gasket.
It may also be possible and practical to define a common gasket ID to suit a range of pipe/flange SDR ratings per pipe DN thus reducing the overall variety of gasket sizes needed to be established. In such cases the calculated ID should consider the worst case pipe bore within the range required.
10.1.2 Rule #2 definition
Define gasket ID based on equivalent metal pipe OD relative to metal backing ring flange standard DN, Class. i.e.) Use ASME B16.21 dimensions or applicable gasket standard.
Recommended for CNAF materials. For these materials ASME B16.21 or applicable companion gasket standard dimensions should be used. Reducing the gasket ID to the mean pipe diameter is NOT best practice for these materials.
Not recommended for elastomeric materials. If gasket IDs equal to those listed for standard metal flanges are used the maximum initial stress of the elastomeric material may be reached at relatively low bolt stress values. See Fig-1 and Fig-2 above for relative scales.
10.2 Gasket thickness
THICKER gaskets DO NOT make better gaskets; this is the common creed of most gasket manufacturers and indeed the FSA and ESA which often goes unheeded. There are numerous valid technical reasons for this but the full discussion of these is outside the scope of this document. The following is a reference to an article covering this topic in detail which was published by FSA (Fluid Sealing Association) in 2005:
What gasket thickness should I use in my pump system?
Sealing Sense Article – Fluid Sealing Association www.fluidsealing.com/sealingsense/Oct05.pdf
The most common gasket thickness used for elastomeric gaskets is 3mm (1/8”). However, these normally only support relatively low operating pressures and this thickness is generally the most common sheet material available in a wide variety of compounds.
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 Bolt load/torque values
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.
Technical report – Gaskets for PE pipe connections v3(Released)
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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 Units Example 1 Example 2
Pipe DN mm 160 160
Pipe Class (per AS4130) PE100 PE100
Pipe SDR 17 17
Operating pressure Bar (MPa)
8 (0.8) 8 (0.8)
Pipe connection type PE to PE PE to PE
Flange/backing ring DN mm 150 150
Backing ring flange standard ASME B16.5 ASME B16.5
Backing ring flange Class Class 150 Class 150
Gasket style Full face Full face
Gasket Rule applied (per table 9)
#1 #2
Gasket ID mm 140.7 168.3
Gasket OD (effective) (1) mm 212 212
Gasket contact stress area mm2 19,751 13,053
No of studbolts ea 8 8
Size of studbolts inch ¾ ¾
PE stub flange OD mm 212 212
Bolt stress area (total) mm2 1745 1745
Bolt stress MPa 112 76
Gasket stress (Initial) MPa 10 10
Gasket stress (Operational) MPa 9.3 8.9
Note:
1) Effective gasket OD is equal to PE stub flange OD for PE-PE connections.
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Table 11- Sample gasket stress vs bolt stress data (CNAF materials)
Detail Units Example 3 Example 4
Pipe DN mm 160 160
Pipe Class (per AS4130) PE100 PE100
Pipe SDR 17 17
Operating pressure Bar (MPa)
16 (1.6) 16 (1.6)
Pipe connection type PE to PE PE to PE
Flange/backing ring DN mm 150 150
Backing ring flange standard ASME B16.5 ASME B16.5
Backing ring flange Class Class 150 Class 150
Gasket style Full face Full face
Gasket Rule applied (per table 9)
#1 #2
Gasket ID mm 140.7 168.3
Gasket OD (effective) (1) mm 212 212
Gasket contact stress area mm2 19,751 13,053
No of studbolts ea 8 8
Size of studbolts inch ¾ ¾
PE stub flange OD mm 212 212
Bolt stress area (total) mm2 1745 1745
Bolt stress MPa 184 135
Gasket stress (Initial) MPa 16.3 18
Gasket stress (Operational) MPa 15 15
Note:
1) Effective gasket OD is equal to PE stub flange OD for PE-PE connections.
12.0 How to order gaskets
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. Nominal PE pipe DN 2. Pipe classification from AS 4130 or pipe standard. I.e.) PE80 or PE100 only 3. SDR rating of pipe and PE stub flange (these are the same) 4. Nominal backing ring DN or NPS 5. 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 ++
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Application data (optional)
++ Instead of these values, if preferred you could supply the gasket manufacturer with the following details, in addition to the information stated above, and they will suggest a suitable gasket for you:
1. Operating media details eg) LNG, Water etc 2. Operating temp (max) 3. Operating pressure (max)
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.
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