At PGE India our Sealing Division is proud to be associated with DONIT Tesnit D.o.o., Slovenia. and their Gasket Installation. We offer certified solutions to reassure you on quality. DONIT follows the similar Gasket Installation Model just like European Sealing Association and Fluid Sealing Association

1. DONIT
GASKET
INSTALLATION

2. Installation Procedure
Assuring:
 joint integrity
and
 maximum safety
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3. Installation Procedure
A guide to successful gasket installation
Successfully sealing a flanged connection is dependent upon all components
of a well-designed flange system working well together
This presentation provides guidance to maintenance operators, engineers
and fitters, to ensure successful gasket installation and assembly of bolted
flange connections
It is intended to complement other plant-approved installation procedures
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4. Installation Procedure
Tools required
Specific tools are required for cleaning and tensioning the fasteners.
Additionally, always use standard safety equipment and follow good safety
practices.
Calibrated torque wrench, hydraulic or other
tensioner
Wire brush (brass if possible)
Helmet
Safety goggles
Lubricant
Other plant-specified equipment
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5. Installation Procedure
Remove all foreign material and debris from:
seating surfaces
fasteners (bolts or studs)
nuts
washers
Use plant-specified dust control procedures
Clean
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6. Installation Procedure
Examine
Examine fasteners (bolts or studs), nuts
and washers for defects such as burrs or
cracks
Examine flange surfaces for warping,
radial scores, heavy tool marks, or anything
prohibiting proper gasket seating
Replace components if found to be
defective.
If in doubt, seek advice
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7.  Surface waviness
 Distortion trough / grooves
 Surface scorings
 Non-parallel flanges
 Other surface imperfections
Challenges prior to installation
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8. Flange surface finish Inspection
Fine ! Damaged !
Scores or grooves
= max. 0.2mm profound and max. over ½ seating width
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9. Flange surface finish
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10. Recommended finish for flange
surfaces
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11. Recommended finish for flange
surfaces
Gasket Description Micro Inch –
CLA
Micrometer
- Ra
Non Asbestos Fibre (NAF) 3,2 – 12,5 125 - 500
PTFE / Modified PTFE 3,2 – 12,5 125 - 500
Graphite Gaskets 1,6 – 12,5 63 - 500
Spiral Wound Gaskets 3,2 – 6,3 125 - 250
Camprofile Gasket 3,2 – 6,3 125 - 250
Metal Jacketed Gaskets 0,3 – 2,5 16 - 100
Solid Metal (RTJ’s) - 0,8 max. - 30 max.
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12. Installation Procedure
The Microsurf series of comparators
This is a range of light-weight comparators more suited to office and design
shop use. Each set in the range is presented in a plastic wallet, with an
instruction card giving full details on the roughness values of the specimens.
Flange Surface
The measurement of surface roughness is not as straightforward as most other engineering measurements,
such as length or angle or hardness; and in order to get good accuracy, expensive instruments are needed.
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13. Installation Procedure
Align flanges
Align flange faces and bolt holes
without using excessive force
Report any misalignment
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14. Installation Procedure
Align flanges
Pipe Size Accepted Tolerance
A Up to 4” (ND100) Max. 2mm
> 4” (ND100) Max.. 3mm
C - B Up to 4” (ND100) Max. 0,5mm
> 4” (ND100) Max. 2,0mm
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15. Installation Procedure
Ensure gasket is the specified size and
material
Examine the gasket to ensure it is free of
defects
Carefully insert the gasket between the
flanges
Make sure the gasket is centred between the
flanges
Do not use jointing compounds or release
agents on the gasket or seating surfaces unless
specified by the gasket manufacturer
Bring flanges together, ensuring the gasket
isn’t pinched or damaged
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16. Installation Procedure
Lubricate load-bearing surfaces
Use only specified or approved lubricants
(check temperature!)
Liberally apply lubricant uniformly to all
thread, nut and washer load-bearing
surfaces
Ensure lubricant doesn’t contaminate
either flange or gasket face
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17. Stud-bolts, bolts and nuts
Stud-Bolts acc. ASTM
Standard: ASME B16.5
Threads : UNC (Unified Coarse) up to 1 inch
UN8 ( 8 threads per inch) from 1 1/8”
Material Grades:
- Stud: ASTM A193-B7
- Nut : ASTM A 194-2H
- Carbon Steel for general purpose
- Temp.range: - 20°C up to 400°C
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18. Install and tighten fasteners
 Always use proper tools:
calibrated torque wrench
or other controlled
tensioning device
 Consult your gasket
manufacturer for guidance
on torque specifications
 Always torque in a cross
bolt tightening pattern

19. Tighten the nuts in multiple steps
 Step 1 - tighten all nuts initially by
hand (larger bolts may require a small
hand wrench
 Step 2 - torque each nut to ~30% of
full torque
 Step 3 - torque each nut to ~60% of
full torque
 Step 4 - torque each nut to full torque,
again still using the cross bolt
tightening pattern (larger diameter
flanges may require additional
tightening passes)
 Step 5 - apply at least one final full
torque to all nuts in a clockwise
direction until all torque is uniform
(larger diameter flanges may require
additional passes)
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20. THANK YOU
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