KLINGER expert 5.1 Powerful Sealing

Calculation

®

The KLINGER ®expert 5.1 gasket design program is a versatile piece

of software to assist users in the selection of

non-metallic gasket materials.

KLINGER – The global leader in static sealing

1. New Calculation

1.1 Menu and Toolbar

The following Icons will guide clear-ly though the many possibilitieswhich KLINGER ®expert 5.1 offers:

FileNew Create a new gasket calculation

Open Opens an existing calculation file

Close Analysis Closes the actual calculation

Save Saves the actual calculation

Save asWill save the actual calculation under a defined name

Print Prints the actual calculation

Print settings Changes the settings for theprintout

Exit Exit the program

OptionsPreferencesOpens the settings

HelpKLINGER ®expert HelpOpens the KLINGER ®expert 5.1 Help

AboutShows information to the program

Read Disclaimer Shows the disclaimer

The KLINGER ®expert 5.1 gasketdesign program is a versatile pieceof software to assist users in theselection of non-metallic gasketmaterials.

The program uses Europeanindustry standard calculations togenerate all information involvedwith selection of suitable materials.

Among the range of functionsthat can be performed are:

Identification of the best gasket material for specificapplications

Design of gasket assemblies

Checks of chemical and temperature suitability

Calculation of bolt torque requirements

Installation

After inserting the CD into the CD-ROM drive it is possible tochoose either to start the KLINGER ®

product catalogue or to start KLINGER ®expert 5.1.

A installation wizard willguide through the set-up processand install KLINGER ®expert 5.1 onthe computer.

After starting KLINGER ®

expert 5.1 an information windowwill appear.

If this message is confirmedwith ‘Accept’ a new window willappear in which the followingpossibilities can be chosen:

Will open an existing calculation file

Here you can change the defaultvalues (i.e. language)

Starts a new gasket calculation

Exits KLINGER®expert 5.1

Open calculation

Preferences

Beginn new analysis

Exit KLINGER expert®

KLINGER®expert 5.1 Powerful Sealing

Calculation

1.2 Flanges

KLINGER®expert 5.1 contains thegasket dimensions and bolting information for a range of standardflanges, including DIN, EN, JIS andANSI standards. KLINGER®expert 5.1can also be used to calculate varia-bles for non standard user definedflanges.

1.3 Gaskets

The dimensions screen can be used to confirm the dimensions ofthe gasket. When using standard designs most of these values arefixed, with the only variable beingthe material thickness. The diagramshows the inner and outer diametersof the gasket and also includes thedimensions of the raised face areawhere applicable. At user-definedflanges the type of gasket has to bechosen.

The first six options for nonstandard flanges require relativelystraightforward variables such as

inner and outer diame-ters, bolt hole sizes andlengths and widths forrectangular gaskets.

The final option”Complex Dimension”requires the area of thegasket to be entered formore complex shapes.

The calculation goes out froma permanent allocation of the bolts.The areas required are the ”Stressedgasket area” and the ”Total area” tobe entered.

■ Stressed gasket area Area of the gasket which will be subjected to compressive load.

■ Total area Area subjected to compressive withthe addition of the enclosedpressurised area.

The type of pressure loading isselected from this screen:

■ Internal pressure relievedThe most common type of applicati-on, when the internal pressure isapplied it has the effect of reducingthe compressive load on the gasket.

■ Internal pressure loadedThe option is sometimes required forboiler man way joints for which thelid of the flange is on the inside ofthe vessel and the internal pressureincreases the compressive load onthe gasket.

1.4 Bolts

Again, like the ‘Dimensions’ screenmost of the bolt details are enteredaccording to the standard and do notneed to be altered. The two valuesthat can be changed are the boltlubrication co-efficient and the boltmaterial.

For non-standard flanges thetype of bolt can first be selectedfrom the option box, this will thenalter the available options in thedimension combo box in the ‘Boltcharacteristics’ area of the screen.

The number, size and qualityof bolt can be identified in theirappropriate boxes; the frictioncoefficient can also be entered.

Figure 4 – Complex shape

Figure 2 – Flange selection

Figure 3 – Gasket dimensions

Other Toolbar Icon’sInfo Opens the Info dialogue

Gasket catalogue Shows the corresponding product datasheet to thechosen Gasket

Select flange Shows the flange selection dialogue

Select gasket dimension Shows the gasket dimension selection dialogue

Restore initial calc. Will restore the initial calculation

Quick HelpOpens the KLINGER®expert 5.1 Quick Help

1.7 Calculation results – The analysis screen

The analysis screen is split in to anumber of areas:

■ Bolt characteristics■ Bolt Forces■ Gasket conditions■ Gasket stresses■ Service conditions■ Leakage■ DIN Leakage

1.7.1 Bolt characteristics

This area displays information concerning the bolts of the flange:

■ Bolt number The number of bolts. This numberwill be set in calculations involvingstandard size flanges.

■ Bolt quality A range of bolt materials are available for selection.

■ 0.2% creep limit The stress applied to the bolt material to attain a permanentdeformation of 0.2%. This value is a property of the selected materialand cannot be independently edited.This value is used in the calculationof the percentage of bolt yield.

■ Size The size of bolts. This will be set for applications involving standardsize flanges.

■ Friction The friction co-efficient of the currently selected bolt material, thelower the value the greater the amo-unt of energy transferred into stret-ching the bolt and not "wasted” inovercoming the friction of the boltthread.

■ TorqueThe level of torque currently selected.

1.5 Medium

The specification of the medium isthe same for both standard and non-standard flanges.The medium can beselected from the drop-down list asshown in figure 5. It is also possibleto choose the medium via the chemical formula.

The temperature, pressure andconcentration of the application canbe typed into the relevant boxes. Theaggregate state can be selected fromthe option box. The required leakrate can be selected; the selection ofa medium will select a standard leakrate classification according to theDIN standard.

1.6 Gasket material selection

On the material selection screenthere are two main options,”Automatic choice” and ”Materialinput”:

■ Automatic choiceThe program selects the correct gas-ket based on the given applicationand the pre adjusted values.

Afterwards please carry out thegasket calculation.

■ Material InputSelecting of the gasket material suit-able for the given application fromthe material table. The chemicalresistance and the maximum per-missible temperature of the selectedgasket material gives a first indica-tion for the suitability of the gasketmaterial.

Afterwards please carry out thegasket calculation.

Figure 6 – Gasket material selection

Figure 5 – Medium selection

If this is not the case, meaning thatthe expected tightness is less thandesired, the installation surface pressure can nevertheless still beadequate under certain circum-stances.Take account of the DINLeakage.

■ Hydrostatic end thrust ∆σp

This value represents the maximumpossible arithmetical reduction orraise of the gasket stress as theresult of the operating pressureduring operation by this value. The inner pressure can raise (+) orlower (-) the surface pressure duringoperation. (Additional reducingof the installation surface stressthrough the real operation conditionse.g. settling of the gasket and reducing of the bolt forces due totemperature influences can not becovered by the calculation and there-fore not be taken into considerationin this software).

■ Effective surface stress σeff

(Important: Value for the installation)The effective surface stress namedhere was determined through thecalculation. It depends upon the entire bolt load which is made available and the gasket area. Equalsurface stress is required over thewhole gasket. Using inner pressureloaded gaskets, the effective surfacestress here determined by the innerpressure and bolt forces too.

This value is an approximatedvalue, because there are some notconsiderable parameters which havean influence on it. Also we presume,that the bolts will be tighten up afterapplying the inner pressure. But youshould pay attention, that the boltsreceive no overload, when decrea-sing the pressure.

■ Minimum surface pressure under operating conditions σBU/L

The minimum surface pressureσBU/L is the surface pressure whichmust be exercised on the effectivegasket area in the operating condi-tion to achieve the desired leakageclass with the given medium, inter-nal pressure, temperature and pre-vious value of σV of the surfacepressure, especially if it is higher.The actual value may not be lessthan this value in operation in anycase.

■ Minimum surface pressureunder installing conditionsσVU/L

At least this surface stress must bereached on the sealing area throughthe bolt forces during assembly toguarantee the leakage requirementsselected (DIN leakage) under thedefined operating conditions.

Because there are limitinginfluences not covered by the calcu-lation one has to take care thatthe real installation surface stresswill be selected safe above σVU/L asa rule. This applies especially forlower σVU/L values (<10 N/mm 2).

σVU/L is a material-specificindex and does not yet take accountof a possible higher necessary mini-mum installation surface pressurewhich will be required because ofthe relief of the gasket through theinternal pressure (cf. σe min )

■ Minimum installing surfacepressure σe min

The minimum installed surface pressure σe min is the surface pres-sure which should be reached withthe installation of the gasket. Itensures that adequate pressure/adaptation of the gasket material isachieved (cf. σVU/L), and that possi-ble dynamic changes of the surfacepressure through the internal opera-ting pressure are taken into account(cf. ∆σp).

This surface pressure shouldbe reached by the effective pressurein view of the necessary tightness.

1.7.2 Bolt forces

The maximum bolt load is calculatedas a function of the material and thebolt material. The yield is a productof the torque applied to the currentbolt with the given friction co-effi-cient.The total bolt force is the sumof the bolt force for the number ofbolts given.

1.7.3 Gasket conditions

The current gasket material, thickness, compressed area andtotal area is displayed and canalso be edited.

1.7.4 Gasket surface pressures

The primary information forchecking the assembly is calculatedand displayed. The definitions of theterms are as follows:

■ Maximum surface pressure under operating conditions σBO

The maximum permissible surfacestress, given in N/mm 2, refers to thegasket material and the stated operating conditions. This value may not be exceeded by the effectivesurface stress.

■ Maximum surface pressureunder installing conditions σVO

σVO in accordance with DIN 28090amounts to the value of σBO atroom temperature. It is always equalto or larger then σBO and therebydoes not represent an additionalrestrictive -limitation in the calcula-tion of the gasket.

The higher the maximum stresscapability of the material the higherthe internal pressure the gasket canwithstand. Sufficient load has to beapplied to the gasket to compressthe material and also counteract theforce due to the internal pressure,generally as the internal pressureincreases, the amount of stressreleased also increases and the initial stress on the gasket must begreater to cater for the releasingeffect of the internal pressure.Once the material is subjected to aload greater than its maximum, thegasket is unlikely to maintain a reliable seal, as the gasket couldundergo a large decrease in thick-ness known as ”crashing”.

1.8.3 Attaining sufficient gasket stress

The compressive load due to thebolts must be sufficient to compressthe material and also counteract therelease of load due to the internalpressure. The torque of the boltsmust be selected to ensure the effec-tive gasket stress σE ff is greaterthan σE min and less than σBO.

Typically the bolts should betorqued to equate to a utilisationfigure of 60-80%. (DIN) ensuring thebolt operates within its elastic regionand will not over-stress the bolt.

1.8 Manipulating results

Possibly the most important factor incorrect operation of a gasket is thestress exerted on the gasket material,this must be sufficient to counteractthe internal pressure and also retainenough stress to compress the mate-rial to effect a reliable seal and alsomust be less than the maximumstress of the material σBO.

1.8.1 Creating a seal

Materials such as compressed fibre,expanded graphite, modified PTFEand some of the harder rubber mate-rials all require a certain degree ofstress to reduce the porosity of thematerial matrix and deform the sur-faces to accommodate imperfectionsin the flange. The stress required tocreate a seal varies from material tomaterial.

1.8.2 Maximum permissiblestress

The maximum stress capability of agasket is dependant on a number offactors such as the temperature,material, thickness and with graphitebased materials in particular thewidththickness ratio. Materials designed for higher pressure dutieshave a much greater maximumstress than other materials.

1.7.5 Service conditions

The currently selected service con-ditions can be viewed and altered,the results of any changes will automatically be calculated and displayed.

1.7.6 Leak Rates

The effective leak rate represents theequivalent nitrogen leakage for thecurrent gasket arrangement by takinginto account bolt forces, internalpressure and the gasket dimensions.The leak rate is calculated at roomtemperature λ20 and the operatingtemperature λT.

1.7.7 DIN leakage

The leak rate is calculated in accor-dance with DIN 28090 and DIN 3535and the currently selected tightnessclass (L= 0.01; L= 0.1; L=1.0).

KLINGER ®expert 5.1 programautomatically defines a leakage ratebased on the media currently selec-ted. The value is calculated for agasket of dimensions 90 x 50 mmwith the current internal pressure,material and thickness.

Figure 7 – Analysis screen

3. Printout

The calculation results as well assome additional information’s con-cerning the gasket materials and theflange connection will be printed onthe hard copy.

There is also the possibility toprint out an additional text.

2.4 Standard values

The ”Presetting” screen is used toselect the preferred or most commonstart-up requirements for the following variables; bolt quality, co-efficient of friction, bolt utilisa-tion, gasket thickness.

2.5 Display

The units for any calculations can bealtered from the ‘Screen’ menu byselecting either SInorm or US-Norm(imperial).

2.6 Printing

Here you have the possibility toenter an additional text. This textwill also be printed out on the hardcopy.

2. Settings

The ”settings” screen can be acces-sed through the ”Options” menu andselecting ”settings”.

Figure 8 – Preferences menu

2.1 Language

The current language used to displayinformation can be altered by selec-ting it via the pulldown menu.

2.2 Price index

The price index in KLINGER®expert5.1 is formed as a ratio of the rela-tive prices on one side and on theapplication frequency of the chosenmaterial on the other side.

The price index is variable andinfluences the position table of thesuitable materials at the automaticchoice.

2.3 Weighting

Materials can be selected in twomain ways; Manual and Automatic.The Automatic option uses the figures entered in this screen toidentify a material. The program can evaluate materials according to3 factors; Function, Price andHandling. A balance can be struckaccording to the opera-tors requirements. Thefunction variable mustbe in the range of 10 to100%, the example infigure 11 shows 100%function and hence willnow select the tech-nically best solution.

Figure 9 – Weighting

We have devised a tried and tested method,

to guide you step by step to the right gasketfor your needs.

1. Applications overview:The gasket characteristics comparedwith the criteria to be met in typicalapplication.

2. Product documentation:A separate data sheet is supplied foreach gasket in our range.The pT diagrams are an invaluableaid to selecting the gasket most suitable for a particular application.

3. Data on chemical resistance:This section indicates the resistanceof the individual Klinger gaskets toover 200 chemicals in common use.

4. Technical information by Fax:Let us have the details of your particular gasket requirements andyou will receive a prompt reply, insome cases within 24 hours.

5. Sealing calculationson your PC:For the experienced specialist wehave developed a powerful programwhich will answer all your questionson gasket construction, design andmaintenance. We supply the softwarewith on-line help.

6. Ideally you should run your own tests:We will supply the materials youneed to carry out tests under yourown operating conditions.

7. On-sit advice:With particularly difficult problemswe shall be glad to advice you on-site. We can supply productsadapted from our existing range orcustom-formulated products.

Rich. Klinger Dichtungstechnik GmbH & Co KGAm Kanal 8-10A-2352 Gumpoldskirchen, AustriaTel ++43 (0) 2252/62599-137Fax ++43 (0) 2252/62599-296e-mail: mueller@klinger.co.athttp://www.klinger.co.at

Subject to technical alterations. Issue: January 2005

Certified according to DIN EN ISO 9001:2000

Powerful sealing calculation withonline help on CD-ROM