Chapter 4

4.2.2. ECM for aboveground closed piping operational gas

emissions

4.2.2.1. Reduction in number of flanges and connectors

Description: Bolted flanges and gasket-sealed joints are used wherever pipes, pumps, or valves
may require isolation or removal.

A primary cause of flange leakage is thermal stress, which causes deformation of the seal
between the flange faces. Thus piping systems in cyclic thermal service are likely to have
higher flange leak rates.

Leaks from flanges may also be caused by misalignment and can be reduced by increased
attention to the bolting technique. The flange rating and the type and material of the gasket
need to be adequate for the service. For example, spiral wound gaskets to reduce risk of failure
on gas systems and primary liquid shutoff valves.

Minimising the number of flanges by replacement with welded connections can be considered,
compatible with the operations and maintenance requirements of the plant.

Threaded connectors may leak if the threads become damaged or corroded or if tightened
without sufficient lubrication or torque. Pipeline standards should set a minimum size of branch
pipeline which can be attached to a main pipeline to protect against mechanical damage, as it is
easy to damage a very small pipeline attached to a very large pipeline.

Achieved environmental benefits: Each flange or flange assembly should meet the design
code requirements to make sure that each flange assembly is able to withstand the maximum
pressure at which the pipeline is to be operated. Meeting the design code requirements also
ensures that the flange will be able to maintain its physico-chemical properties at any
temperature to which it is anticipated that it might be subjected to in service.

Operability: Bolted and gasketted flanges are required wherever pipes, pumps, or valves may
require isolation or removal. It is thus not possible to remove all flanges and connectors from a
transfer and handling system.

Applicability: Widely applicable, within the limitation of operational requirements for

equipment maintenance or transfer system flexibility.

Safety aspects: None.

Energy/waste/cross-media: None.

Economics: Minimising the number of flanges by replacement with welded connections,

compatible with the operations and maintenance requirements of the plant, is a low cost option
for new systems. Retrofitting is medium to high cost.

Reference literature: [152, TETSP, 2002]

4.2.2.2. Selection and maintenance of gaskets

Description: Correct selection of the gasket and regular maintenance (e.g. controlled tightening
of the flange), are very important to prevent emissions. The regular control and replacement of
the gaskets is also necessary, especially for those gaskets exposed to temperature fluctuation or
vibration (where gasket load may be lost).

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Primarily, a proper selection must be based upon:

compatibility with the operating medium (process fluid)

operating temperature and pressure
variations of operating conditions (for example, during cycling)
the type of joint involved.

Gaskets can be defined into three main categories:

soft (non-metallic)
semi-metallic
metallic.

The mechanical characteristics and sealing performance capabilities of these categories will
vary extensively, depending on the type of gasket selected and the materials from which it is
manufactured. Obviously, mechanical and sealing properties are important factors when
considering gasket design, but the selection of a gasket is usually influenced primarily by:

temperature and pressure of the medium to be contained

chemical nature of the medium
mechanical loading affecting the gasket
sealing characteristics of the gasket.

Soft gaskets (non-metallic)
Often composite sheet materials, suitable for a wide range of
general and corrosive chemical applications. Generally limited
to low to medium pressure applications. Types include: fibre
reinforced sheet, exfoliated graphite, sheet PTFE
(polytetrafluoroethylene) in various forms (including blow-out
resistant forms based upon orientation of the PTFE) and high
temperature sheet materials based upon forms of mica.

Semi-metallic gaskets Composite gaskets consisting of both metallic and non-metallic

materials, the metal generally providing the strength and
resilience of the gasket. Suitable for both low and high
temperature and pressure applications. Types include: covered
serrated metal cored, covered metal jacketed, covered
corrugated metal, metal eyelet, metal jacketed, metal reinforced
soft gaskets (including tanged graphite and wire reinforced
fibre materials), corrugated metallic and spiral wound gaskets.

Metallic gaskets Can be fabricated from a single metal or a combination of

metallic materials, in a variety of shapes and sizes. Suitable for
high temperature and pressure applications. Types include:
lens rings, ring type joints and weld rings.

A good performing gasket must be resistant to deterioration from the fluids being sealed, and it
must be compatible chemically and physically. For metallic gaskets, consideration must be
given to electrochemical (or galvanic) corrosion, which can be minimised by selecting gasket
and flange metals which are close together on the electrochemical series.

Gaskets cut from sheets perform best when using the thinnest material that the flange
arrangement will allow, but thick enough to compensate for unevenness of the flange surfaces,
their parallelism, surface finish and rigidity, etc. The thinner the gasket, the higher the bolt load
that the gasket can withstand, the less the loss of bolt stress due to relaxation, and hence the
longer the service life of the gasket. Also, the lower the gasket area which will be exposed to
attack from the internal pressure and aggressive media.

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Once assembled, a gasket must be capable of overcoming minor alignment and flange
imperfections, such as:

non-parallel flanges
distortion troughs/grooves
surface waviness
surface scorings
other surface imperfections.

When assembled, a flange gasket seal is subject to compressive pressure between the faces of
the flanges, usually achieved by bolts under tension. In order to ensure the maintenance of the
seal throughout the lifetime of the assembly, sufficiently high pressure must remain on the
gasket surface to prevent leakage. Under operating conditions, this pressure will be relieved by
hydrostatic end thrust, the force produced by internal pressure which acts to separate the
flanges. The gasket itself is also subject to a side load due to the internal fluid pressure tending
to extrude it through the flange clearance space. To maintain seal integrity, the effective
compressive pressure on the gasket (that is, the assembly load minus the hydrostatic end thrust)
must be greater than the internal pressure by some multiple, dependent upon the gasket type,
manufacturing process involved and level of tightness required.

For spiral wound gaskets in particular, the flatness and parallelism of the flanges are important
factors for good sealing performance.

For soft gaskets, there must also be adequate friction between the gasket and flange faces to
help prevent extrusion (blow-out) of the gasket from the joint. To allow for any relaxation of
gasket compressive pressure which is normally inevitable, a factor of at least two is usually
recommended between the compressive pressure on the assembly and that required to maintain
a seal.

A proper assembly procedure is important for a good sealing performance; detailed guidance on
this can be found in reference: [149, ESA, 2004]

Gaskets are normally not re-used because they may have been modified dramatically under
operating conditions and might not achieve the normal level of sealing performance. Anyhow,
the costs for new gaskets are very low.

High-integrity gaskets are, e.g. spiral wound, kammprofile or ring joints.

Exfoliated graphite and processed PTFE sealing materials have proved to be very successful
when applied to a whole range of gasket styles providing the user with sealing performance way
beyond that of the original asbestos-based gaskets.

Reference literature: Guidelines for safe seal usage Flanges and Gaskets (ESA publication
no. 009/98), available in several language versions. [149, ESA, 2004]

4.2.2.3. Improved flanges

Description: For installations with a high potential for environmental pollution, flanges with
tongue and groove or with projection and recess, or special seals such as those with metal or
grooved seals, are common practice.

Reference literature: [18, UBA, 1999]

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