Gasket Installation — Tools and Step-by-Step Procedure

I. Tools required for installation

Cleaning and tightening fasteners require a range of specific tools. In addition, only standard installation equipment should be used and good safety practices must be observed at all times.

Prepare the following equipment before beginning installation:

  • Calibrated torque wrench, hydraulic torque wrench, or other torque-controlled tightening tools;

  • Steel wire brush (brass brush preferred where appropriate);

  • Hard hat;

  • Safety goggles;

  • Lubricant;

  • Any other factory-specified tools.

II. Gasket installation steps

1. Inspection and cleaning

  • Remove all foreign matter and debris from the gasket seating faces and from all fasteners (bolts, stud bolts), nuts and gaskets.

  • Inspect fasteners, nuts and gaskets for burrs, cracks or other defects.

  • Check flange faces for distortion or warpage, radial scoring, deep impact marks from tools, or any other defects that could prevent the gasket from seating correctly.

  • Defective components must be replaced promptly. If there is any doubt about whether replacement is required, consult the gasket manufacturer.

2. Flange alignment

  • Align flange faces and bolt holes.

  • Report promptly any condition that prevents proper alignment.

3. Gasket placement

  • Verify the gasket is the specified size and material.

  • Inspect the gasket to ensure it is free of defects.

  • Carefully insert the gasket between the two flanges.

  • Confirm the gasket is centered between the flanges.

  • Do not apply adhesives or anti-stick compounds unless specifically required by the gasket installation instructions.

  • Align the flange faces and ensure the gasket is not nicked or cut during handling.

4. Lubricate load-bearing surfaces

  • Only the specified or approved lubricants are permitted on load-bearing areas.

  • Apply sufficient lubricant to all threads, nuts and gasket load faces.

  • Ensure the lubricant does not contaminate the flange face or the gasket sealing surface.

5. Bolt installation and tightening

  • Always use the correct tools.

  • Use a calibrated torque wrench or other torque-controlling tightening tool.

  • Consult the gasket manufacturer’s technical department for torque requirements and specifications.

  • Tighten nuts using the “cross-pattern” (crisscross) sequence.

Five-step nut tightening procedure:

  1. Initial hand-tightening of all nuts. Larger nuts may be brought up with a small hand wrench.

  2. Tighten each nut to approximately 30% of the required final torque.

  3. Tighten each nut to approximately 60% of the required final torque.

  4. Using the cross-pattern, tighten each nut to 100% of the required final torque.

    • Note: For large-diameter flanges, the above steps may be repeated in additional increments.

  5. Perform at least one final pass by tightening each nut sequentially in a clockwise direction until the required full torque is reached.

6. Re-torquing (after initial operation)

  • Note: Consult the gasket manufacturer’s technical department for guidance and recommendations on re-torquing.

  • Non-asbestos gaskets and gaskets containing rubber compounds that have been exposed to high temperatures must not be re-torqued (unless otherwise specified).

  • Fasteners exposed to corrosion or thermal cycling will require re-torquing.

  • Any re-torquing operations should be performed at ambient temperature and atmospheric pressure.

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