Right onTopAnewera in

gasket technology

KLINGER – The global leader in static sealing

www.klingerquantum.com

A Vision Becomes RealityThe development of KLINGER®Quan-tum germinated from the vision ofdeveloping an asbestos-free, fibre-reinforced gasket material that wouldbehave in a similar, problem-freemanner at high temperatures to theearlier KLINGERit. Moreover, thismaterial would fulfil the contempo-rary, trendsetting requirements fortightness and environmental compa-tibility.

The first groundbreaking step inthe development of an asbestos-freefibre gasket was the presentation andmarket launch of KLINGERSIL® in1982. Since then, KLINGERSIL® ma-terials have established themselvesin the market and proven themselvesa million times over. Many applicati-ons are today simply not conceivablewithout these materials.

Nonetheless, so far, fibre-rein-forced materials generally have notbeen able to fulfil the expectations ofmany users with regard to flexibilityat higher temperatures.

Since the change-over to asbestos-free fibre gaskets, many usershave been on the look-out for agasket material with the outstan-ding high-temperature propertiesof the asbestos-containing mate-rial KLINGERit.As the leading manufacturer of

static gasket materials, Klingerwas the pioneer in the develop-ment of asbestos-free fibre reinfor-ced gaskets.The best achieved so far was the

market launch of KLINGER®top-sil-ML1, which, although it was alarge step forward, did not reachthe really challenging ultimategoal.With the development of

KLINGER®Quantum, Klinger isnow heralding a new era in theworld of gasket technology.

KLINGER®Quantum is the first fibre-reinforced gasketmaterial in the world that is exclusively HNBR-bound.

Together with a unique production process developedspecially for the purpose, this material can be used athigher temperatures and with a much wider range of mediathan any other fibre-reinforced gasket material that iscurrently available.

1

Being a world-wide marketleader, KLINGER was therefore conti-nuously involved in finding a solu-tion to this problem and in 2004,exactly 111 years after the inventionof KLINGERit, presented the ground-breaking material KLINGER ®top-sil-ML1.

The patented, futuristic multi-layer concept resulted in an exten-sion of service life at high tempera-tures.

HNBR was used for the firsttime as the binding agent in fibre-reinforced gasket materials in com-bination with NBR.

From the experience gained inthis development and a focused,consistent further development ofthe production process came thebreakthrough: in 2009, KLINGERrevolutionized the capability of fibregaskets with the launch of the uni-que sealant material KLINGER ®

Quantum.

Flexibility at High TemperaturesThe 3-point bending test is oftenused as an evaluation method for theflexibility of fibre-reinforced gasketmaterials. Special tests on condi-tioned specimens provide an indi-cation of the brittleness and hence ofthe aging behaviour of the elastomersused.

Before the test, the specimensare first conditioned and subse-quently tested.

The results of thetests on these artificiallyaged test specimens pro-vide information on theaging resistance of thedifferent material concepts.

Particularly in steamapplications, pressureshocks frequently occur,which result in damage tothe gasket material.A more flexible gasket that

can overcome extensive expansionwithout fracture is a decisive factor inobtaining a more reliable gasket joint.

In this test, KLINGER ®Quantumshows its uniqueness and outstan-ding position as compared to allother available fibre-reinforcedgasket materials. The flexibility ofKLINGER ®Quantum at higher tempe-ratures is several times higher thanthat of traditional fibre-reinforcedgasket materials.

All the negative aspects of flatgaskets such as embrittlement, crackformation and increased leakage canbe reduced significantly by the use ofKLINGER ®Quantum.

The handling of the material issimilar to that of the known fibre-reinforced materials and is thereforefamiliarly simple.

The Outstanding PropertiesKLINGER ®Quantum offers a formerlyunknown level of flexibility for fibre-reinforced gasket materials at highcontinuous temperatures, with asimultaneously improved chemicalresistance and a broader range ofapplications than all known fibre-reinforced gasket materials.

Of course, KLINGER ®Quantumfulfils all the present-day require-ments for tightness and safety.

A new era in gasket technology

Life

time

Temperature

KLINGER ®Quantum

Material A

Treatment of the samples:48h at 200°C1. Standard fibre reinforced material2. KLINGER ®Quantum

1

2

The many, varied demandsplaced on gasketsA common perception is that thesuitability of a gasket for anygiven application depends uponthe maximum temperature andpressure conditions.

This is not the case.

Maximum temperature andpressure values alone can notdefine a material’s suitability foran application. These limits aredependent upon a multiplicity offactors as shown in the diagramopposite.

It is always advisable toconsider these factors whenselecting a material for a givenapplication.

* Gaskets according to DIN 2690 are only standardisedup to PN 40 and gasket thickness 2 mm.

Selecting gaskets withpT diagramsThe Klinger pT diagram providesguidelines for determining thesuitability of a particular gasketmaterial for a specific applica-tion based on the operatingtemperature and pressure only.Additional stresses such asfluctuating load may signifi-cantly affect the suitability of agasket in the application andmust be considered separately.

Always refer to the chemicalresistance of the gasket to thefluid.

Processcontrol

Tempe-rature

Flange

Medium

Pressure

Bolt

In area one, the gasketmaterial is normally suitablesubject to chemical compati-bility.

In area two, the gasketmaterials may be suitable but atechnical evaluation is re-commended.

In area three, do not installthe gasket without a technicalevaluation.

Areas of Application

Klinger Hot and ColdCompression Test MethodThe Klinger Hot CompressionTest was developed by Klingeras a method to test the loadbearing capabilities of gasketmaterials under hot and coldconditions.

In contrast to the BS 7531and DIN 52913 tests, the KlingerCompression test maintains aconstant gasket stress through-out the entire test. This subjectsthe gasket to more severe condi-tions.

The thickness decrease ismeasured at an ambient tempe-

The diagram showsadditional thickness decrease at temperature.

Surface pressure MPa Tempe

rature

°C

Hotc

ompr

essi

on%

Hotc

ompr

essi

on%

Temperatures up to 400°Care then applied and the additi-onal thickness decrease ismeasured. This simulates thefirst start up phase.

rature of 23°C after applyingthe gasket load. This simulatesassembly.

KLINGERQuantumFlanged joint integrity

®

Gasket factor QSmax according toEN 13555QSmax is the maximum surface pres-sure that may be imposed on the gas-ket at the indicated temperatureswithout collapse or compressive fai-lure of the gasket.

The determination of QSmax mayfor sheet materials result in an over-estimation of the capability of thegasket sheet and it is important thatall values of QSmax for sheets areverified by conducting a test for PQRat the same temperature and surfacepressure as for the QSmax-value.

Temp.°C

23

100

200

300

QSmax

200

200

120

100

60 MPa

>0.99

0.88

0.82

0.72

40 MPa

>0.99

0.85

0.83

0.82

PQR 500k N/mm

0.99

0.77

0.72

0.64

Thickness Reduction at QSmaxThe specification of the thicknessreduction of the tested gasket ma-terial results in a better evaluation ofwhether the material is suitable forthe given application or not.

The thickness reduction of thegasket material is measured at theend of every load cycle of the QSmaxtest and results in the followingdiagram:

Thic

knes

sde

crea

se

100°C

200°C300°C

23°C

Surface Pressure MPa20

100

200

300

400

500

600

700

40 60 80 100 120 140 160 180 200

800

Q Smax

MPa

Temperature °C

23°C100°C

200°C300°C

0

20

40

60

80

100

120

140

160

180

200

220

200 200

120

100

Elasticity Module EG according toEN 13555This gasket characteristic is deter-mined from the thickness recovery ofthe gasket between the initial com-pression surface pressure and unloa-ding to a third of the initial surfacepressure.

The determination is made fromthe unloading cycles of the QSmaxtest. The value for EG changes withthe surface pressure on the gasket.

A high EG value means a smallrecovery, and a low EG value means ahigher recovery and is thus an indi-cation of a lesser embrittlement of thematerial.

than known fibre-reinforced gasketmaterials!

Particularly in steam applicati-ons, there are often strong pressureshocks that result in damage to thegasket material. A more flexible gas-ket that withstands greater expan-sions without rupture is thus a factorthat contributes to a safer, morereliable gasket joint.

The unique behaviour ofKLINGER ®Quantum manifests itselfeven more impressively in long-termtests. For this purpose, a fibre-rein-forced reference material, togetherwith KLINGER ®Quantum was againtreated at a temperature of 200°C for300 h and 600 h.

After 600 hours at a temperatureof 200°C KLINGER ®Quantum showsa flexibility that is 8 times higher

Bending Test according to ISO 178To evaluate flexibility potentials ofsealing materials the three pointbending test is often used to assessthe flexibility of compressed fibrematerials.

In this test, the test specimen isdeformed in the middle between thecontact faces with a constant testingspeed until it breaks, or until thedeformation has reached a specifiedvalue.

For the flexibility test, specimensof a fibre-reinforced reference mate-rial and of KLINGER ®Quantum weretreated for 48h at 200°C and at250°C.

The results of the test on theseartificially aged samples provide in-formation on the aging resistance ofthe two different materials andunderscore the high performance ofKLINGER ®Quantum.

200°C

300°C

23°C

Surface pressure MPa

Elas

ticity

Mod

ule

MPa

201000

1500

2000

2500

3000

40 60 80 100 120 140 160 180 200

KLINGER ®Quantum Standard fibrereinforced material

200°C/ 48h

250°C/ 48h

Bend

ing

stra

in%

0

1

2

3

4

5

6

7

8

98,83

6,83

4,10

0,57

200°C/ 300 h

200°C/ 600 h

Bend

ing

stra

in%

0

1

2

3

4

5

6

7

8

9

Standard fibrereinforced material

KLINGER ®Quantum

7,17

6,37

0,83 0,80

KLINGERQuantumFlanged joint integrity

Important points to be observedWith heightened awareness of safetyand environmental issues, reducingleaks from flanged assemblies hasbecome a major priority for industry.It is therefore important for companieswho use gaskets to choose thecorrect material for the job and installand maintain it correctly to ensureoptimum performance.

A flanged joint will remain tightas long as the surface pressure inservice is higher than the minimumsurface pressure required to achievethe necessary levels of tightnessbut is lower than the maximumpermissible surface pressure. Butincreasingly high demands on thetightness requirements for flangedjoints (e.g. Tightness class 0.01)necessitate the application of highloads on the gasket material in orderto meet these stringent requirements.

If the gasket is to be subjectedto non-static loading and stressfluctuations due to temperatureand pressure cycling, it is advisableto select a gasket material which isless prone to embrittlement withincreasing temperatures(e.g.KLINGER®graphit Laminat,KLINGER®top-chem, KLINGER®top-sil,KLINGER ®Quantum).

In cyclic loading conditions werecommend a minimum surfacestress of 30 MPa and that the gasketshould be as thin as is practicable.

For safety reasons never re-usegaskets.

Leakage curve ofKLINGER®Quantumat a temperature of23°C and aninternal pressure of40 bar

Leakage curve ofKLINGER®Quantumat a temperature of200°C and aninternal pressure of40 bar

Surface Pressure MPa

Thickness 2.0 mmp = 40 barT = 23°CHe

T

leak

age

rate

mg/

mx

s

01.00E-06

1.00E-04

1.00E-02

20 40 60 80 100 120

1.00E-05

1.00E-03

1.00E-01

1.00E+00

Surface Pressure MPa

leak

age

rate

mg/

mx

s

0

1.00E-05

1.00E-04

1.00E-03

20 40 60 80 100 1201.00E-06

1.00E-02

1.00E-01

1.00E+00

Thickness 2.0 mmp = 40 barT = 200°CHe

l

Gasket factor QSmin accordingto EN13555(Tightness at high temperatures)QSmin describes the requiredminimum surface pressure on thegasket under operating conditions,i.e. upon relief during operation atoperating temperature, so that thenecessary leakage class L is main-tained for the given internal pressure.

During the test, the gasket mustbe cyclically strained and relieved,with the leakage rate being measuredat a surface pressure defined in thestandard at an internal pressure of40 bar.

Helium has to be used as testinggas for this test.

®

KLINGERQuantumInstallation instructions

®

The following guidelines aredesigned to ensure the optimumperformance of our gasket materials:

1. Choosing the gasketThere are many factors which mustbe taken into account when choosinga gasket material for a given applica-tion including temperature, pressureand chemical compatibility.

Please refer to the informationgiven in our brochure or, for adviceto our software program KLINGER®

expert.If you have any questions regar-

ding the suitability of material for agiven application please contactKlinger Technical Department.

2. Gasket thicknessThe gasket should be as thin astechnically practical. To ensureoptimum performance a minimumthickness/width ratio of 1/5 isrequired (ideally 1/10).

3. Flange conditionEnsure all remains of old gasketmaterials are removed and theflanges are clean, in good conditionand parallel.

4. Gasket compoundsEnsure all gaskets are installed ina dry state, the use of gasketcompounds is not recommended asthis has a detrimental effect on thestability and load bearing characte-ristics of the material.

When torquing, tighten bolts inthree stages to the required torque asfollows:Finger tighten nuts. Carry outtightening, making at least threecomplete diagonal tightening se-quences i.e. 30%, 60% and 100%of final torque value. Continue withone final pass – torquing thebolts/studs in a clockwise sequence.

8. RetighteningProvided that the above guidelinesare followed retightening of thegasket after joint assembly shouldnot be necessary.

If retightening is considerednecessary, then this should only beperformed at ambient temperaturebefore or during the first start-upphase of the pipeline or plant.Retightening of compressed fibregaskets at higher operating tempera-tures and longer operating timesmay lead to a failure of the gasketconnection and possible blow out.

9. Re-useFor safety reasons never re-use agasket.

Powerful sealing calculationwith online help onCD-ROM

In its uncompressed form thegasket can absorb liquid, and thismay lead to failure of the gasket inservice.

To aid gasket removal Klingermaterials are furnished with a nonsticking finish.

In difficult installation conditions,separating agents such as dry spraysbased on molybdenum sulphide orPTFE e.g. KLINGER®flon spray, maybe used, but only in minimal quanti-ties.

Make sure that the solventsand propellants are completely eva-porated.

5. Gasket DimensionsEnsure gasket dimensions are correct.The gasket should not intrude into thebore of the pipework and should beinstalled centrally.

6. BoltingWire brush stud/bolts and nuts(if necessary) to remove any dirt onthe threads. Ensure that the nuts canrun freely down the thread before use.Apply lubricant to the bolt andto the nut threads as well as to theface of the nut to reduce frictionwhen tightening.

We recommend the use of a boltlubricant which ensures a frictioncoefficient of between 0.10 to 0.14.

7. Joint AssemblyIt is recommended that the bolts aretightened using a controlled methodsuch as torque or tension, this willlead to greater accuracy and con-sistency than using conventionalmethods of tightening. If using atorque wrench, ensure that it isaccurately calibrated.

For torque settings please referto the KLINGER®expert or contact ourTechnical Department which will behappy to assist you.

Carefully fit the gasket intoposition taking care not to damagethe gasket surface.

KLINGERQuantumTechnical data

50 MPa, 16h/ 300°C50 MPa, 16h/ 175°C40 MPa, 16h/ 300°CThickness decrease at 23°CThickness decrease at 300°CThickness decrease at 400°CDIN 28090-2300°C/30 MPaDIN 28090-2DIN 28090-2DIN 28090-2DIN 28090-2Oil IRM 903: 5 h/150°CFuel B: 5 h/23°CDIN 28090-2FA-GAZF712122B3E22M5Grade AX

Typical values for a thickness of 2.0 mmCompressibility ASTM F 36 JRecovery ASTM F 36 JStress relaxation DIN 52913

Stress relaxation BS 7531 1.5 mmKLINGER cold/hot compression50 MPa

TightnessSpecific leakrate VDI 2440Cold compressionCold recoveryHot compressionHot recoveryThickness increase after fluidimmersion ASTM F 146DensityDesignation DIN 28091-2ASTM F104 line call-outClassification acc BS 7531

1060283227101420

< 0.024.4 10E-8

6 - 93 - 5< 18

235

1.7

%%

MPaMPaMPa

%%%

mg/s x mmbar x l/s x m

%%%%%%

g/cm3

� ApplicationUnique gasket material with the hig-hest flexibility at high temperatures,manufactured from a high-qualityfibre and filler compound.

A high temperature-resistantHNBR matrix is used as the bindingagent. Suitable for use in oils, water,steam, gases, salt solutions, fuels,alcohols, weak organic and inorganicacids, hydrocarbons, lubricants andrefrigerants.

� Dimensions of the standardsheetsSizes:1,000 x 1,500 mm, 2,000 x 1,500 mmThicknesses: 0.8 mm, 1.0 mm,1.5 mm, 2.0 mm, 3.0 mmother thicknesses and sizes onrequest.Tolerances:thicknes ±10%, length ± 50 mm,widt ± 50 mm

� SurfacesThe gasket materials are generallyfurnished with surfaces of lowadhesion. On request, graphitefacings and other surface finishes onone or both sides are also available.

� Function and durabilityThe performance and service life ofKLINGER gaskets depend in largemeasure on proper storage andfitting, factors beyond the manufac-tor’s control. We can, however, vouchfor the excellent quality of our pro-ducts.

With this in mind, please alsoobserve our installation instructions.

� Tests and approvalsBAM tested II-611/2009,KTW proposal,DIN-DVGW certificate,DIN-DVGW W270,HTB acc. to VP401,Fire-Safe,FDA conformity,TA-Luft (clean air) acc. VDI 2440,Germanischer Lloyd,ÖVGW certificate,WRc/WRAS

KLINGER GmbHRich.-Klinger-Straße 37D-65510 IdsteinPhone +49 (0) 6126-4016-0Fax +49 (0) 6126-4016-11/-22e-mail: mail@klinger.dehttp://www.klinger.de

Subject to technical alterations.Issue: February 2013

Certified according toDIN EN ISO 9001:2008

®

Powerful sealing calculationwith online help onCD-ROM

02.1

3-w

ww.w

ampe

r-gr

afik

desi

gn.c

om