Gaskets ensure leak-free vessel performance

Edited by the Engineeringtalk editorial team May 15, 2006

An increase in the report of gasket failures has prompted Novus Sealing to raise a concerned voice over the need place quality before price.

An increase in the report of gasket failures has prompted Novus Sealing to raise a concerned voice over the need place quality before price.

Novus Sealing, formed from a management buyout of the Econosto gasket business, is echoing the concerns of senior process engineers and members of the heat transfer industry who have to deal with the consequences of poor quality products.

Many concerns surround the Camprofile gasket, once a bastion of reliability and automatic choice for difficult service.

Dr Gavin Smith leads the Novus Sealing Technical Team.

"It is both surprising and alarming that in a relatively short space of time the Camprofile gasket has become so devalued", says Dr Smith.

"We are conscious that Camprofile gaskets, often selected for arduous and critical service are sourced with little or no sympathy for the production requirements of the gasket let alone meeting design criteria and function".

"Many users subsequently are looking to us to investigate problems and we are finding significant quality issues and manufacturing defects that represent a genuine cause for concern".

"In one recent instance leak paths had been created by weld grinding, in another the gasket had completely collapsed when welds failed and in another gasket no less than eight welds were found in a gasket diameter of less than 1.5 metres".

"We have also seen a recovered gasket that had no cams machined into the pass ribs".

The Novus Technical Support Team covers all aspects of sealing from nonasbestos jointing through to metallic and semimetallic gaskets and gives hands on practical advice to the user that includes gasket selection, design studies, inspection services and training.

The team also oversees Camprofile production to ensure highest compliance standards.

Novus Sealing has invested extensively in the production of Camprofile gaskets, which were developed by Hofland and Econosto who were responsible for much of the development of the gasket and its capabilities.

The Novus Sealing production facility in West Yorkshire includes two massive centre lathes that can accommodate Camprofile gaskets turned in one piece, up to 3m in diameter either from sheet material or a single welded ring, this is unique in the UK.

Considerable investment has also been made in welding preparation and dressing equipment that ensures that where welds in gaskets are required they are minimised and perfectly match the surrounding material, so even when a weld is the last resort, the investment in procedures, machinery and inspection creates a weld which is totally compatible to the surrounding material.

Similar concerns surround metal-jacketed gaskets where complex manufacturing requirements are time consuming and costly.

Novus Sealing recognised that even with the most modern facilities metal-jacketed gaskets are inherently a poor gasket design and made a conscious decision to switch production to the Dynagraph gasket, which entirely replaces jacketed and soft gaskets in heat exchangers and vessels.

Dynagraph gaskets eliminate the quality problems created by poor welding of the jacket and any pass ribs, similarly Dynagraph does not suffer from stress cracks and will tolerate a lower flange finish and reduce fugitive emissions.

Managing Director Mark Neal comments: "In creating Novus Sealing I saw that the business had two great assets, one was a first class manufacturing unit and the other was the best technical team in Europe to back it up".

"We have invested heavily in both machinery and new products to meet a challenging market place".

"I believed then and even more now, that Novus Sealing produce top class products with complete technical support and the confidence of our clients".

"Novus Sealing gaskets will always be manufactured up to a standard and not down to a price; unfortunately too many users who are not so selective can see initial low unit costs being eaten up by higher maintenance costs, shorter gasket life and even joint failure".

Novus Sealing has created an exchanger programme that offers the client a complete range of services to ensure leak free vessel performance using high quality gaskets designed expressly for the task.

This unique service encompasses vessel survey and analysis, bolt and flange stress analysis, gasket recommendation, in house manufacturing, personnel training, recording and emission testing and recording.