How to Fix a Flange Gasket Leak in Piping Systems

June 18, 2021

 
There is nothing worse than being woken up in the middle of the night because of a leak in your piping system… and more often than not, gaskets get the blame! In this post, we’ll be looking at some of the most common issues that lead to flange gasket leaks and how to address them.

Application leaks in piping systems can be dangerous and expensive but at the same time, preventable. Unforeseen expenses due to loss of production, increased maintenance costs, and fines, could be devastating to a company.

Flange leaks caused by gasket failures can happen for a variety of reasons:

  • Under compression
  • Over compression
  • Uneven compression
  • Re-usage of gaskets
  • Chemical Attack

Let’s take a step back and talk about the mechanics of bolting; where a force is applied thru the flange to create a seal. This will compress and densify the gasket, reduce porosity, create a sealing barrier at the gasket ID, and will prevent fluid from penetrating and degrading the gasket.

Examples of Flange Joint Leakage and Gasket Failures

Overtightening

What to look for:

  • Extrusion of gasket from the flange
  • Irregular-shaped gasket
  • Inward buckling of Spiral Wound Gaskets that contain inner rings
  • Imprints on the centering rings

What to expect:

  • Reduced gasket contact area causing the gasket to crush toward the ID
  • Fluid “pooling” around the ID which can lead to deterioration of the gasket
  • Damaged flanges

Remedy:

  • Plant Wide Bolting Procedure as referenced in ASME PCC-1
  • Gasket Torque Values based on the type of gasket material being used

Under tightening

What to look for:

  • Little or no flange serration marks
  • Little change in gasket thickness after being compressed

What to expect:

  • Fluid to penetrate gasket ID leading to deterioration of gasket
  • Gasket Blowout
  • Gasket Leakage

Remedy:

  • Plant Wide Bolting Procedure as referenced in ASME PCC-1
  • Changing bolting material

Re-use/Double Compression

What to look for:

  • Multiple compression lines/double patterns

What to expect:

  • Gasket Leakage

Remedy:

  • Stop the re-use of gaskets

Chemical Attack

What to look for:

  • Gasket Cracking
  • Softening of Material
  • Tearing
  • Erosion of Material
  • Uneven material discoloration

What to expect:

  • Gasket Leakage

Remedy:

  • Review chemical compatibility
  • Updating storage visual aids to identify different types of gasket materials
  • Improve storage requirements

It is important to always contact the gasket manufacturer to ensure the right gaskets are being used in each application.

If there is any confusion about required information for your application, please fill out our Gasket Application Data Sheet so we may further assist you. We also hope you’ve learnt a thing or two, or at least what steps to take if you’re faced with a flange gasket leak in your piping systems. For more information on anything gasket related, please give us a call, we’d like to hear from you.