KC Sealing System Design Objectives

Transcription

1 KC Sealing System Design Objectives These are the objectives our UPW customers have told us are most important to them. We tried to meet these objectives in designing the KC Sealing System and believe they are important for end-users to consider in evaluating flange component alternatives. We are not aware of any combination of components other than those in the KC Sealing System which meet these objectives. Seal the joint. Seal the joint at bolt-up, during testing and during operation. Seal the joint at the pipe ID, not just at the flange face OD. You only see leaks at the flange face OD. Even though there are no visible signs of a leak, you may have medium trapped between each side of the gasket and the face of opposing flanges. Eliminate areas in which bacteria can grow: Seal at ID of the flange. Fit the flange both before and after bolt-up. Create no pockets at pipe ID under normal operating conditions. Minimize voids in the gasket material. Minimize gasket exposed area and compressed (installed) thickness. Provide even stress distribution on the gasket and flange area. Minimize total cost of installed flange, not just purchase cost of components at the receiving dock. Installation cost includes purchase cost of a flange backing ring, gasket, fasteners and mechanical contractor crew cost (labor, tools, scaffolding and clean room) and project elapsed time. Costs at the receiving dock are the most critical costs only if flange components are never installed. Arrive at dock cleaned and ready to install. Simplify installation procedure. Reduce installation time. Reduce chances for installation error, while making allowance for such errors. Seal at pipe manufacturer s torque values without requiring costly fasteners (higher grade and/or PTFEcoated) or bolt lubricants, which cause higher stresses on flanges. Reduce re-installation costs to fix leakers during purge and testing. Help to geometrically center the pipe for proper laminar flow. Minimize the hydraulic forces which the joint must overcome - you do this by sealing at the flange ID, not the flange OD. Eliminate the distortion, and subsequent thermal set, of flange adapters caused by conventional flange backing rings. Manufacture gasket from as pure a material as possible. Mass produce components. Achieve predictable, reliable, repeatable, measurable and verifiable joint performance.

2 We didn t set out to design the best UltraPure Water sealing system but we did. Flanged joints notoriously have been the weakest link in any piping system. This is especially true, and critical, in ultra-pure water (UPW) systems used in today s precision manufacturing of semiconductor, pharmaceutical, and bio-technology products. Some gaskets are right on size before installation, but protrude into the stream flow after bolt-up (elastomeric materials). This causes turbulence and dead spots which may provide an area for bacteria to grow, contaminating your water system, and possibly your finished product. Do you know whether the gasket you are currently using protrudes into the stream flow, and may be causing some of your purity problems? A gasket which is widely used in UPW applications is dark green when installed, but becomes lavender over time. Did you ever wonder where in your UPW system the coloring finally ended up, and if this might be causing purity problems? Other backing flanges concentrate clamping force on the outside of the flange face, rather than on the I.D. of the pipe. This results in a seal on the outside of the flange face, but reduced compression at the most critical point - the I.D. of the pipe. While there may be no externally-visible signs of leakage, this may create an internal breeding ground for costly contaminants along side of the gasket. Did you know that the combination of certain widely used backing flanges and PTFE over EPDM gaskets may allow the medium to come in contact with the EPDM substrate? Properly installed backing flanges are bolted-up in a star pattern. Some piping and valve manufacturers suggest maximum torquing for each pipe size and also recommend a 4-pass bolt-up, using a calibrated torque wrench for the final pass. The only sure way to get a good joint is to do a 4-pass bolt up using 33% of the value for each pass and use a calibrated torque wrench for the final pass, but you must also measure the gasket compression using a feeler gauge. This ensures that the seal is good before the system is hydro tested and gaskets get wetted. KC Sealing System Gaskets: UltraPure For non metalic piping (full-face and ring). For Schedule 10 piping. For Old and New ANSI piping. Other materials available include: Viton, FPM, EPDM; and Silicone Installation Tools: Both ANSI and DIN Read on to learn how KC s Sealing System can help you maintain the integrity of your critical piping system. The KC Sealing System consists of an innovative patented low-torque gasket, engineered patented backing flanges. We would be happy to discuss your sealing issues and problems, and how we can help you resolve them. Let us explain to you why today s leading-edge UPW systems have KC Multi-Ring Products inside and outside.

3 Table of Contents GASKETS... 1 GENERAL SERVICE GASKETS AND SPECIALTY GASKETS... 2 backing flanges... 3 BENEFITS... 4 INSTALLATION INSTRUCTIONS... 5 CONVERSIONS... 6 LIMITED WARRANTY... 7

4 Gaskets 1 KC Multi-Ring UltraPure Gaskets Introduction Part Number Designation Reference ANSI - Pre-Densified Expanded PTFE Universal UltraPure Gasket DIN - Pre-Densified Expanded PTFE Universal UltraPure Gasket DIN - Pre-Densified Expanded PTFE Universal UltraPure Gasket DIN - Expanded PTFE Universal UltraPure Gasket a Pre-Densified Expanded PTFE Butt-Weld UltraPure Gasket Pre-Densified Expanded PTFE Socket Fusion UltraPure Gasket Expanded PTFE Schedule 10 UltraPure Gasket Pre-Densified Expanded PTFE Schedule 10 UltraPure Gasket Expanded PTFE New ANSI UltraPure Full Face Gasket Expanded PTFE New ANSI UltraPure Ring Gasket Expanded PTFE Old ANSI UltraPure Full Face Gasket Expanded PTFE Old ANSI UltraPure Ring Gasket Universal UltraPure KRYSTLE-CLEAR Gasket Schedule 10 UltraPure KRYSTLE-CLEAR Gasket New ANSI UltraPure Full Face KRYSTLE-CLEAR Gasket New ANSI Ring UltraPure KRYSTLE-CLEAR Gasket Old ANSI UltraPure Full Face KRYSTLE-CLEAR Gasket Old ANSI UltraPure KRYSTLE-CLEAR Ring Gasket Installation Procedure for UltraPure Gaskets

5 We didn t set out to design the best UltraPure Water sealing system but we did. KC Multi-Ring UltraPure Gaskets A line of expanded PTFE and elastomeric gaskets engineered using our patented design to fit your piping. Our gaskets are an integral part of the KC Sealing System of gaskets and flange backing rings. KC Multi-Ring Products, Inc. gives the UPW user the most comprehensive and best-designed system for sealing and installing critical flanged joints. Great care has been taken to provide a leak-free seal and laminar flow at piping and valve manufacturer s recommended bolt load torque. Our gasket design also provides nearly equal gasket compression around the entire flange face. Gaskets are cleaned at our factory, and shipped in individually sealed bags for cleanliness until installation. Each bag is clearly marked with part number and description. The patented KC Multi-Ring design provides a positive seal at up to 5.0% lower bolt load than conventional gaskets of like material. Our gasket is engineered to provide an equal clamping force around the entire flange face. KC Multi-Ring UltraPure gaskets are available in fullface universal and ring styles. Since the universal gasket can be used with both socket fusion and buttweld flange adapters, you only have to manage one inventory. The ring style design is available for either socket fusion or butt-weld flange adapters. and bagged) for Schedule 10 piping frequently found in water conditioning systems. The KC Multi-Ring design is available for Old ANSI and New ANSI styles for all of your gasketing needs. The same torque value (per pipe size) is used for universal and ring-style and New ANSI raised-face gaskets. UltraPure gaskets are available in expanded PTFE and elastomeric materials. Non-UltraPure gaskets can be manufactured from any other gasket material, including FPM, EPDM and many others. Competitive Advantages: Seals at a lower bolt load torque. Seals evenly around the entire flange face. Does not just seal at the outside of the flange face. Does not introduce any coloring contamination into your system. Does not protrude into the stream flow after bolt-up. Manage only one inventory with universal. Use one torque value for the entire job site. Optimal results are achieved when used with KC Multi-Ring s flange rings. KC Multi-Ring gaskets are available (also cleaned 1-1

6 The following part number designation is to be specified when ordering or referring to KC Multi-Ring 1 gaskets. The information in the brackets is detailed below and describes the part number format: [1] [2] [3.] [4] KC-.. Example: KC-.AG = old ANSI dimension, 1/8. expanded PTFE, UltraPure, 3., 15.0#, full face gasket KC.GG9.110=DIN Standard dimension, 1/8. expanded PTFE, UltraPure, densified, 4, 15.0#, universal ring gasket [1] GASKET DIMENSIONS A = Old Standard ANSI nominal ID in inches B = DIN Standard pipe size designation in MM - Ring gasket for IR/BCF Flange D = Fiberglass Reinforced Plastic Ducting per NBSPS E = DIN Standard pipe size designation in MM - DIN PN 16 bolt pattern F = DIN Standard pipe size designation in MM - DIN PN 10 bolt pattern G = DIN Standard pipe size designation in MM - Universal gasket - ANSI 15.0# Bolt Pattern K = JIS Standard pipe size designation in MM - JIS 10K Bolt Pattern L = JIS Standard pipe size designation in MM - JIS 5.K Bolt Pattern N = New Standard ANSI for all schedule of metallic slip-on flanges - gasket ID = OD of IPS S = DIN Standard pipe size designation in MM - Ring gasket for Socket Fusion Flange T = Schedule 10 - for Sch. 10 weld neck flanges and stub ends - gasket ID = ID of Sch. 10 IPS [2] GASKET MATERIAL [3] SERVICE / APPLICATION E = 1/8. EPDM 0 = General Service G = 1/8. Expanded PTFE 8. = UltraPure - cleaned and bagged K = 1/8. KRYSTLE-CLEAR 9 = UltraPure densified and embossed V = 1/8. Viton 2 cleaned and bagged (DIN and Schedule 10) many others available [4] GASKET SIZE AND PRESSURE RATING 150 lb. Rated 300 lb. Rated 3 ANSI Metric Ring Full Face 4 Ring Full Face 4 1/2 20MM /4 25MM MM /4 40MM /2 50MM MM /2 75MM MM / MM MM MM MM MM MM MM MM MM MM MM NOTES: 1 KC Multi-Ring is the trademark of KC Multi-Ring Products, Inc. 2 Viton is the registered trademark of the DuPont Corp. 3. DIN Standard gaskets not available in 3.00 lb. ring. 4 Full Face - Material encompasses flange bolts. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-2

7 ANSI - Pre-Densified Expanded PTFE Universal UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe J K L Thickness Bolt Bolt Bolt Size mm Part # I.D. O.D. inch inch Circle Hole Hole inch inch inch Diameter # Diameter ½ 20 KC-.GG /8 ¾ 25 KC-.GG / KC-.GG /8 1 ¼ 40 KC-.GG /8 1 ½ 50 KC-.GG / KC-.GG /4 2 ½ 75 KC-.GG / KC-.GG / KC-.GG /4 ANSI - Pre-Densified Expanded PTFE Universal UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe J K Thickness Bolt Bolt Bolt Size mm Part # I.D. O.D. inch Circle Hole Hole inch inch inch Diameter # Diameter KC-.GG / KC-.GG / KC-.GG / KC-.GG / KC-.GG ANSI - Expanded PTFE Universal UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe J K Thickness Bolt Bolt Bolt Size mm Part # I.D. O.D. inch Circle Hole Hole inch inch inch Diameter # Diameter KC-.GG KC-.GG KC-.GG KC-.GG KC-.GG Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure expanded PTFE gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-3

8 DIN - Pre-Densified Expanded PTFE Universal UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with DIN PN 10 and 16 bolt pattern. Pipe J K Bolt Bolt Bolt Size PN Part # I.D. O.D. L Circle Thickness Hole Hole mm mm mm mm Diameter mm # Diameter KC-.EG KC-.EG KC-.EG KC-.EG KC-.EG KC-.EG KC-.EG KC-.EG KC-.EG DIN - Pre-Densified Expanded PTFE Universal UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with DIN PN 10 and 16 bolt pattern. Pipe J K Bolt Bolt Bolt Size PN Part # I.D. O.D. Circle Thickness Hole Hole mm mm mm Diameter mm # Diameter KC-.FG KC-.FG9.211a KC-.EG KC-.FG KC-.FG KC-.EG KC-.FG KC-.FG Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure expanded PTFE gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-4

9 DIN - Expanded PTFE Universal UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with DIN PN 10 and 16 bolt pattern. Pipe J K Bolt Bolt Bolt Size PN Part # I.D. O.D. Circle Thickness Hole Hole mm mm mm Diameter mm # Diameter KC-.FG KC-.FG KC-.FG KC-.FG KC-.FG KC-.FG Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure expanded PTFE gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-4a

10 Pre-Densified Expanded PTFE Butt-Weld UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Pipe Size J K L Thickness PN mm Part # mm mm mm mm KC-.BG KC-.BG KC-.BG KC-.BG KC-.BG KC-.BG KC-.BG KC-.BG KC-.BG KC-.BG KC-.BG9.111a * KC-.BG * KC-.BG * KC-.BG * KC-.BG * 3 * Not used with these sizes Pre-Densified Expanded PTFE Socket Fusion UltraPure Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) Socket Fusion Type Flange Adapter. Pipe Size J L Thickness PN mm Part # mm mm mm KC-.SG KC-.SG KC-.SG KC-.SG KC-.SG KC-.SG KC-.SG KC-.SG KC-.SG Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure expanded PTFE gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-5

11 Expanded PTFE Schedule 10 UltraPure Gasket For use with Stainless Steel Weldneck Type Flange Adapters. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe J K Bolt Bolt Bolt Size Part # I.D. O.D. Circle Thickness Hole Hole inch inch inch Diameter inch # Diameter ¾ KC-.TG ¼ KC-.TG KC-.TG KC-.TG KC-.TG KC-.TG KC-.TG Pre-Densified Expanded PTFE Schedule 10 UltraPure Gasket For use with Stainless Steel Weldneck Type Flange Adapters. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe J K Bolt Bolt Bolt Size Part # I.D. O.D. Circle Thickness Hole Hole inch inch inch Diameter inch # Diameter ½ KC-.TG KC-.TG ½ KC-.TG KC-.TG ½ KC-.TG KC-.TG KC-.TG KC-.TG KC-.TG KC-.TG KC-.TG Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure expanded PTFE gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-6

12 Expanded PTFE New ANSI UltraPure Full Face Gasket Bolt holes in accordance with ANSI B16.5 class 150 pattern. Gasket dimensions per ANSI B Pipe I.D. O.D. Bolt Thickness Bolt Size Part # inch inch Circle inch Hole Diameter inch J K Diameter # ½ KC-.NG ¾ KC-.NG KC-.NG ¼ KC-.NG ½ KC-.NG KC-.NG ½ KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG Expanded PTFE New ANSI UltraPure Ring Gasket Gasket dimensions per ANSI B Pipe I.D. O.D. Thickness Size Part # inch inch inch inch J K ½ KC-.NG ¾ KC-.NG KC-.NG ¼ KC-.NG ½ KC-.NG KC-.NG ½ KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG KC-.NG Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure expanded PTFE gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-7

13 Expanded PTFE Old ANSI UltraPure Full Face Gasket Bolt holes in accordance with ANSI B16.5 class 150 pattern. Gasket dimensions per ANSI B Pipe I.D. O.D. Bolt Thickness Bolt Hole Size Part # inch inch Circle inch Hole Diameter inch J K Diameter # ½ KC-.AG8.201 ½ ¾ KC-.AG8.202 ¾ KC-.AG ¼ KC-.AG ¼ ½ KC-.AG ½ KC-.AG ½ KC-.AG ½ KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG Expanded PTFE Old ANSI UltraPure Ring Gasket Gasket dimensions per ANSI B Pipe I.D. O.D. Thickness Size Part # inch inch inch inch J K ½ KC-.AG8.101 ½ ¾ KC-.AG8.102 ¾ KC-.AG ¼ KC-.AG ¼ ½ KC-.AG ½ KC-.AG ½ KC-.AG ½ KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG KC-.AG Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure expanded PTFE gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-8

14 Universal UltraPure Krystle-Clear Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe I.D. O.D. L Thickness Bolt Bolt Bolt Size mm Part # inch inch inch inch Circle Hole Hole inch J K Diameter # Diameter ½ 20 KC-.GK /8 ¾ 25 KC-.GK / KC-.GK /8 1 ¼ 40 KC-.GK /8 1 ½ 50 KC-.GK / KC-.GK /4 2 ½ 75 KC-.GK / KC-.GK / KC-.GK /4 Universal UltraPure Krystle-Clear Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe I.D. O.D. Thickness Bolt Bolt Bolt Size mm Part # inch inch inch Circle Hole Hole inch J K Diameter # Diameter KC-.GK / KC-.GK / KC-.GK / KC-.GK KC-.GK KC-.GK KC-.GK KC-.GK KC-.GK Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure KRYSTLE-CLEAR (elastomeric) gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-11

15 Schedule 10 UltraPure KRYSTLE-CLEAR Gasket For use with Stainless Steel Weldneck Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe I.D. O.D. Thickness Bolt Bolt Bolt Size Part # inch inch inch Circle Hole Hole inch J K Diameter # Diameter ½ KC-.TK /8 ¾ KC-.TK /8 1 KC-.TK /8 1 ¼ KC-.TK /8 1 ½ KC-.TK /8 2 KC-.TK /4 2 ½ KC-.TK /4 3 KC-.TK /4 4 KC-.TK /4 6 KC-.TK /8 8 KC-.TK /8 10 KC-.TK KC-.TK KC-.TK /8 16 KC-.TK /8 18 KC-.TK /4 20 KC-.TK /4 24 KC-.TK /8 1 Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure KRYSTLE-CLEAR (elastomeric) gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-12

16 New ANSI UltraPure Full Face KRYSTLE-CLEAR Gasket Bolt holes in accordance with ANSI B16.5 class 150 pattern. Gasket dimensions per ANSI B J K L Thickness Bolt Holes Pipe Size Part # inch inch inch inch Number Dia. 1/2 KC-.NK /8 3/4 KC-.NK /8 1 KC-.NK /8 1 ¼ KC-.NK /8 1 ½ KC-.NK /8 2 KC-.NK /4 2 ½ KC-.NK /4 3 KC-.NK /4 4 KC-.NK /4 6 KC-.NK /8 8 KC-.NK /8 10 KC-.NK KC-.NK KC-.AK /8 16 KC-.AK /8 18 KC-.AK /4 20 KC-.AK /4 24 KC-.AK /8 New ANSI Ring UltraPure KRYSTLE-CLEAR Gasket Gasket dimensions per ANSI B J K Thickness Pipe Size Part # inch inch inch 1/2 KC-.NK /4 KC-.NK KC-.NK ¼ KC-.NK ½ KC-.NK KC-.NK ½ KC-.NK KC-.NK KC-.NK KC-.NK KC-.NK KC-.NK KC-.NK KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure KRYSTLE-CLEAR (elastomeric) gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-13

17 Old ANSI UltraPure Full Face KRYSTLE-CLEAR Gasket Bolt holes in accordance with ANSI B16.5 class 150 pattern. Gasket dimesions per ANSI B J K Thickness Bolt Holes Pipe Size Part # inch inch inch Number Dia. 1/2 KC-.AK / /8 3/4 KC-.AK / /8 1 KC-.AK /8 1 ¼ KC-.AK ¼ /8 1 ½ KC-.AK ½ /8 2 KC-.AK /4 2 ½ KC-.AK ½ /4 3 KC-.AK /4 4 KC-.AK /4 6 KC-.AK /8 8 KC-.AK /8 10 KC-.AK KC-.AK KC-.AK /8 16 KC-.AK /8 18 KC-.AK /4 20 KC-.AK /4 24 KC-.AK /8 1 Old ANSI UltraPure KRYSTLE-CLEAR Ring Gasket Gasket dimensions per ANSI B J K Thickness Pipe Size Part # inch inch inch 1/2 KC-.AK / /4 KC-.AK / KC-.AK ¼ KC-.AK ¼ ½ KC-.AK ½ KC-.AK ½ KC-.AK ½ KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK KC-.AK Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring low torque design UltraPure KRYSTLE-CLEAR (elastomeric) gasket, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners, no thread lubricants. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 1-14

18 INSTALLATION PROCEDURE FOR KC MULTI-RING ULTRAPURE GASKET The gaskets will arrive cleaned and individually packaged in sealed bags. Each bag will be labeled with a part number which will correlate with pipe type(s) and dimension. Gaskets of similar size and type will be aggregated and packaged in a larger sealed bag, typically in groups of ten (10). Installation 1. When installation is required, verify that the gasket is the proper size and flange type. When installing the gasket, installer shall wear appropriate garments to meet the appropriate clean zone protocol in effect at the time. Specifically, clean room gloves are to be worn at all times while handling gaskets. 2. While gasket is in the individually sealed bag, inspect for any surface deformations such as tears, rips, or non-uniform cuts. Any material defect of the inner surface is cause for rejection. 3.. If a gasket is rejected due to a surface deformation, place aside for return and specify reason for rejection. 4. Great care should be taken to protect the gasket surface from exposure to oil or other contaminants. 5.. Remove gasket from bag. 6. Immediately prior to installing, pay particular attention to the inner surface. Do not wipe the surface with or expose the surface to IPA (Isopropyl Alcohol) Pay particular attention to keeping the gasket and flange adapters on the same axis (that is, geometrically centered). Install all flanges using a calibrated torque wrench. Whenever possible, apply the torque to the nut. Tighten the flanges in a star pattern to the following torque values using progressive 4-pass tightening. Following the star pattern, torque each nut to 3.3.% of the desired torque value. Then re-torque to 66% of the desired torque value. Re-torque to 100% of the desired torque value. Wait two minutes and re-torque to 100% value. 9. Using a clean feeler gauge select a pair of blades that add up to 5.4 or /1000 s. If you can get the feeler gauge into the notch then the seal is not certain and you will need to make another pass. If after that it is still not compressed to <5.4/1000 s then up the force by 2% and make another pass. The use of the feeler gauge to measure compression is the only certain way to measure if the KCMR expanded PTFE gasket is sealed. Note: Optimal results are obtained when KC Multi-Ring gaskets are used in conjunction with KC Multi-Ring AC backing flanges. 1-15

19 Relying on torque alone does not allow for all the variations that can happen in the field. Torque alone does not measure the force that is applied to the gasket. Variations in nuts and bolts, ability to access the flange fittings, tension due to slight misalignment all compromise being able to rely on torque alone as the measure of gasket compression. Using a feeler gauge on the KCMR Patented notch assures there has been enough force to cause the gasket to seal. A.125. eptfe gasket needs to be compressed to less than.05.5./1000 s to assure seal. Using the feeler gauge will avoid leaks at hydro-testing which are much harder to seal later. Install procedure for KCMR gasket 1-15a

20 Install procedure for KCMR gasket 1-15b

21 Install procedure for KCMR gasket 1-15c

22 General Service Gaskets and Specialty Gaskets Universal FPM Gasket Universal EPDM Gasket EPDM Socket Fusion Ring Gasket EPDM Fiberglass Reinforced Plastic Ducting Gasket Gasket Selection Matrix For Dissimilar Flanges

23 Universal FPM (e.g. Viton 1 ) Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe I.D. O.D. L Thickness Bolt Bolt Size inch inch inch inch Hole Hole inch mm Part# J K # Diameter 1/2 20 KC-.GV /8 3/4 25 KC-.GV / KC-.GV /8 1 ¼ 40 KC-.GV /8 1 ½ 50 KC-.GV / KC-.GV /4 2 ½ 75 KC-.GV / KC-.GV / KC-.GV /4 Universal FPM (e.g. Viton 1 ) Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe I.D. O.D. Thickness Bolt Bolt Bolt Size inch inch inch Circle Hole Hole inch mm Part# J K Diameter # Diameter KC-.GV KC-.GV KC-.GV KC-.GV KC-.GV KC-.GV KC-.GV KC-.GV KC-.GV Viton is the registered trademark of DuPont Corp. Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Gaskets shall be manufactured in the patented KC Multi-Ring low torque design, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 2-1

24 Universal EPDM Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe I.D. O.D. L Thickness Bolt Bolt Size inch inch inch inch Hole Hole inch mm Part# J K # Diameter 1/2 20 KC-.GE /8 3/4 25 KC-.GE / KC-.GE /8 1 ¼ 40 KC-.GE /8 1 ½ 50 KC-.GE / KC-.GE /4 2 ½ 75 KC-.GE / KC-.GE / KC-.GE /4 Universal EPDM Gasket For use with non-metallic piping (PVDF, polypropylene, etc.) IR Butt-Weld Type Flange Adapter. Bolt holes in accordance with ANSI B16.5 class 150 pattern. Pipe I.D. O.D. Thickness Bolt Bolt Bolt Size inch inch inch Circle Hole Hole inch mm Part# J K Diameter # Diameter KC-.GE KC-.GE KC-.GE KC-.GE KC-.GE KC-.GE KC-.GE KC-.GE KC-.GE Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Gaskets shall be manufactured in the patented KC Multi-Ring low torque design, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 2-2

25 EPDM Socket Fusion Ring Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. J K Thickness Pipe Size mm Part # inch inch inch 1/2 20 KC-.SE /4 25 KC-.SE KC-.SE /4 40 KC-.SE /2 50 KC-.SE KC-.SE /2 75 KC-.SE KC-.SE KC-.SE FPM Socket Fusion Ring Gasket For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. J K Thickness Pipe Size mm Part # inch inch inch 1/2 20 KC-.SV /4 25 KC-.SV KC-.SV /4 40 KC-.SV /2 50 KC-.SV KC-.SV /2 75 KC-.SV KC-.SV KC-.SV Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Gaskets shall be manufactured in the patented KC Multi-Ring low torque design, KC Multi-Ring Products, Inc., sole source. To ensure proper laminar flow, geometrically align gasket and flange faces. Install using zinc-plated fasteners. Tighten fasteners in a star pattern, using progressive 4-pass tightening, to proper torque values. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 2-3

26 EPDM Fiberglass Reinforced Plastic Ducting Gasket For use on fiberglass reinforced plastic (FRP) ducting NBSPS J K Thickness Bolt Circle Bolt Holes Pipe Size Part # inch inch inch inch Number Dia. 2 KC-.DE /2 3 KC-.DE /2 4 KC-.DE /2 6 KC-.DE /2 8 KC-.DE /2 10 KC-.DE /2 12 KC-.DE /2 14 KC-.DE /2 16 KC-.DE /2 18 KC-.DE /2 20 KC-.DE /2 24 KC-.DE /2 30 KC-.DE /2 36 KC-.DE /2 42 KC-.DE /2 48 KC-.DE /8 54 KC-.DE /8 60 KC-.DE /8 66 KC-.DE /8 72 KC-.DE /8 78 KC-.DE /8 84 KC-.DE /8 Our gaskets are covered under US Patent #5,362,115 and Others Pending. SAMPLE SPECIFICATION Gaskets shall be manufactured from 1/8 commercial grade 40 durometer EPDM cut to FRP ducting NBSPS 15-69, in patented KC Multi-Ring low torque design, KC Multi-Ring Products, Inc., sole source. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 2-4

27 GASKET SELECTION MATRIX FOR DISSIMILAR FLANGES Select pipe size on left columns, then read left to right until you find both mating flanges and use the gasket that is farthest to the right: Example 1: 4 Old ANSI flange mated to 110 mm DIN Standard use Old ANSI gasket Example 2: 2 Schedule-10 flange to 63 mm DIN Standard flange use DIN Standard gasket I.P.S. mm 1/2 20 OLD ANSI DIN SCH-10 NEW ANSI 3/4 25 OLD ANSI DIN SCH-10 NEW ANSI 1 32 OLD ANSI DIN SCH-10 NEW ANSI 1 1/4 40 OLD ANSI DIN SCH-10 NEW ANSI 1 1/2 50 OLD ANSI SCH-10 DIN NEW ANSI 2 63 OLD ANSI SCH-10 DIN NEW ANSI 2 1/2 75 OLD ANSI SCH-10 DIN NEW ANSI 3 90 OLD ANSI DIN SCH-10 NEW ANSI 3 1/2 OLD ANSI SCH-10 NEW ANSI DIN OLD ANSI SCH-10 NEW ANSI 5 OLD ANSI SCH-10 NEW ANSI DIN OLD ANSI SCH-10 NEW ANSI OLD ANSI DIN SCH-10 NEW ANSI DIN OLD ANSI SCH-10 NEW ANSI 2 12 OLD ANSI SCH-10 NEW ANSI NEW ANSI 14 SCH-10 OLD ANSI or NEW ANSI 16 SCH-10 OLD ANSI or NEW ANSI 18 SCH-10 OLD ANSI or NEW ANSI 20 SCH-10 OLD ANSI or NEW ANSI 24 SCH-10 OLD ANSI or NEW ANSI DIN = DIN Standard Dimensions 2-5

28 Installation INSTALLATION PROCEDURE FOR AC BACKING FLANGE 1. Inspect box for damage from shipping. Notify carrier of any damage and make claims as required. 2. After removing the AC Backing Flange from the box, inspect the beveled surface between the AC Backing Flange inside diameter (ID) for any sharp protrusion which could come into contact with the flange adapter. Any sharp edge in this area is cause for rejection. 3. When installation is required, verify that each AC Backing Flange is the proper size, flange type, and coating for the given application. 4. If AC Backing Flange is rejected due to a surface deformation in the above noted area, set aside for return and specify reason for rejection. 5. Slip AC Backing Flange over flange adapter and rotate ring to confirm correct fit and size. Note: Beveled surface on AC Backing Flange faces flange adapter; washers, bolts, and nuts go on flat surface of AC Backing Flange. As with any flange made to ANSI drilling, optimal distribution of clamping force is obtained through the use of heavy-duty washers. 6. Select one AC Backing Flange on each joint for determining the flange tightening sequence, and follow the star pattern for all tightening passes on that joint. 7. Install all AC Backing Flanges using a calibrated torque wrench or a KC Multi-Ring SmartBox. Whenever possible, apply the torque to the nut. All passes are to be made following the tightening sequence described above. For pass 1, torque each nut to 33% of the desired torque value. For pass 2, re-torque each nut to 66% of the desired torque value. For pass 3, re-torque each nut to 100% of the desired torque value. Wait two minutes and re-torque to 100% value. (Note that for speed and ease of installation, the KC Multi-Ring SmartBox is calibrated to the recommended bolt torque for each pipe size using KC Multi-Ring gaskets, allowing the use of an electric impact wrench for the first 3 passes - a calibrated torque wrench is always used for the final Quality Control pass.) Note: Optimal results are obtained when used in conjunction with KC Multi-Ring reduced surface area low-torque gaskets. 2-6

29 AC Flange Backing Rings Introduction ANSI - AC Springer Steel Flange Ring DIN - Steel Flange Ring Installation Procedure for AC Backing Flanges...3-4

30 We didn t set out to design the best UltraPure Water sealing system......but we did. KC Multi-Ring AC Flange Backing Rings A line of steel backing flanges engineered using our patented design. The backing flanges are an integral part of the KC Sealing System of gaskets and flange backing rings. For Existing piping systems, we split the flanges before coating. This extends the benefits of the KC Sealing System to existing piping systems. KC Multi-Ring Products, Inc. gives the UPW user the most comprehensive and best-designed system for sealing and installing critical flanged joints. The KC Multi-Ring backing flange directs the clamping force toward the pipe I.D. - eliminating any crevice at the joint that could potentially trap contaminants. Comparative tests on 225mm/9 piping run at our stateof-the-art sealing test facility indicate that after bolt-up, conventional backing flanges deflect and single-point load the outside edge of the pipe flange, creating its seal on only approximately the last 1/4 of the flange face. With conventional backing flanges, the clamping force is approximately 2 outside of the pipe I.D. This in turn allows the flange face to deflect at pressures greater than 105 psig (lower than most users initial hydro test) which allows hydro test medium and contaminants to be trapped between the flange face and the gasket surface. This is an ideal breeding ground for bacteria after the hydro test and flushing sequence. These contaminants may be introduced into the system to contaminate the end product, or plug down-stream filters, whenever the pressure at any joint is raised above 105 psig by water hammering when valves open and close during normal system operation. This loading has been known to distort the flange adapter, resulting in a cupped thermal set, particularly when installed with elastomeric gaskets. The KC Multi- Ring flange ring design, which directs the clamping force toward the pipe I.D., eliminates this flange distortion and will, over time, return a cupped flange adapter to its original flat state. Conventional backing flanges have been known to distort the flange adapter, resulting in a cupped thermal set, particularly when installed with elastomeric gaskets. The KC Multi-Ring backing flange design, which directs the clamping force toward the pipe I.D, eliminates this flange distortion and will, over time, return a cupped flange adapter to its original flat state. Our tests further indicate that when the PTFE over EPDM gasket is used with conventional backing flanges, the clamping force is directed outside of the PTFE cover, which may allow the medium to contact the EPDM substrate. On the other hand, the KC Multi-Ring backing flange is loaded at a point at or near equilibrium. This means that equal, or near equal, clamping force is distributed from the I.D. to the O.D. All the while, the point of contact remains at a given point during tightening of the flange bolts. Independent Finite Element Analysis results show better loading and less flange stress than conventional backing rings, and the KC Multi-Ring gasket is stressed equally and maintains a seal at the I.D. of the pipe. Properly installed, there should be little or no bacteria breeding ground with the KC Multi-Ring UltraPure gasket installed with the KC Multi-Ring AC backing flange. Unlike conventional flange backing rings, the KC Multi-Ring flange ring provides a positive seal before, during, and after hydro test and flushing, and, most importantly, during system operation. The KC Multi-Ring flange backing rings will make any gasket seal better than standard backing flanges. Best results are obtained when our flange is combined with the equal gasket compression characteristics of our KC Multi- Ring UltraPure Gasket. Competitive Advantages: Clamping force is directed to the pipe I.D. with standard non-engineered flange backing rings. AC flange backing rings improve the performance of any gasket. Optimal results are achieved when used with KC Multi-Ring s UltraPure Gasket. Available in the following: thermoplastic coated steel galvanized steel primered steel stainless steel. 3-1

31 ANSI - AC Springer Steel Flange Ring For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes drilled in accordance with ANSI B16.5 class 150 pattern. O.D. I.D Thick Bolt Bolt Bolt Pipe Size mm Part # inch inch inch Circle Hole Hole inches A B C inch # Diameter ½ 20 ACS.F02.0zz ¾ 25 ACS.F02.5zz ACS.F03.2zz ¼ 40 ACS.F04.0zz ½ 50 ACS.F05.0zz ACS.F06.3zz ½ 75 ACS.F07.5zz ACS.F09.0zz ACS.F11.0zz ACS.F12.5zz ½ 140 ACS.F14.0zz ACS.F16.0zz ACS.F20.0zz ACS.F22.5zz ACS.F25.0zz ACS.F31.5zz ACS.F35.5zz ACS.F40.0zz ACS.F45.0zz ACS.F50.0zz zz - indicates the Backing Flange Construction: CS - Thermoplastic coated Steel SS - Stainless Steel GS - Galvanized Steel PS - Primered Steel NOTE: BEVELED SIDE CONTACTS flange adapter and nuts, bolts and washers ARE INSTALLED AGAINST THE flat side. Our backing flanges are covered under US Patent #5,716,083 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring thermoplastic-coated AC backing rings, KC Multi-Ring Products, Inc., sole source. ANSI Class 150 bolt pattern. Install with bevel facing flange adapter. Also available in stainless steel, galvanized and red oxide primered. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 3-2

32 DIN - Steel Flange Ring For use with non-metallic Metric piping (PVDF, polypropylene, etc.) IR Butt-Weld and Socket Fusion Type Flange Adapter. Bolt holes drilled in accordance with DIN PN 10 and 16 bolt pattern. Pipe Size A B C D Bolt Holes PN mm Part # mm mm mm mm Number Dia ACx.F02.0zz ACx.F02.5zz ACx.F03.2zz ACx.F04.0zz ACx.F05.0zz ACx.F06.3zz ACx.F07.5zz ACx.F09.0zz ACx.F11.0zz ACx.F12.5zz ACx.F14.0zz ACx.F16.0zz ACx.F16.0zz ACx.F20.0zz ACx.F22.5zz ACx.F22.5zz ACx.F25.0zz ACx.F28.0zz ACx.F31.5zz ACx.F35.5zz x - indicates the Backing Flange Style: G - DIN PN 16 Standard H - DIN PN 10 Standard zz - indicates the Backing Flange Construction: CS - Thermoplastic coated Steel SS - Stainless Steel GS - Galvanized Steel PS - Primered Steel NOTE: BEVELED SIDE CONTACTS flange adapter and nuts, bolts and washers ARE INSTALLED AGAINST THE flat side. Our backing flanges are covered under US Patent #5,716,083 and Others Pending. SAMPLE SPECIFICATION Patented KC Multi-Ring thermoplastic-coated AC backing rings, KC Multi-Ring Products, Inc., sole source. DIN PN 10 and 16 bolt pattern. Install with bevel facing flange adapter. Also available in stainless steel, galvanized and red oxide primered. Contact KC Multi-Ring Products, Inc. for sizes and materials not listed. 3-3

33 Installation INSTALLATION PROCEDURE FOR AC BACKING FLANGE 1. Inspect box for damage from shipping. Notify carrier of any damage and make claims as required. 2. After removing the AC Backing Flange from the box, inspect the beveled surface between the AC Backing Flange inside diameter (ID) for any sharp protrusion which could come into contact with the flange adapter. Any sharp edge in this area is cause for rejection. 3. When installation is required, verify that each AC Backing Flange is the proper size, flange type, and coating for the given application. 4. If AC Backing Flange is rejected due to a surface deformation in the above noted area, set aside for return and specify reason for rejection. 5. Slip AC Backing Flange over flange adapter and rotate ring to confirm correct fit and size. Note: Beveled surface on AC Backing Flange faces flange adapter; washers, bolts, and nuts go on flat surface of AC Backing Flange. As with any flange made to ANSI drilling, optimal distribution of clamping force is obtained through the use of heavy-duty washers. 6. Select one AC Backing Flange on each joint for determining the flange tightening sequence, and follow the star pattern for all tightening passes on that joint. 7. Install all AC Backing Flanges using a calibrated torque wrench or a KC Multi-Ring SmartBox. Whenever possible, apply the torque to the nut. All passes are to be made following the tightening sequence described above. For pass 1, torque each nut to 33% of the desired torque value. For pass 2, re-torque each nut to 66% of the desired torque value. For pass 3, re-torque each nut to 100% of the desired torque value. Wait two minutes and re-torque to 100% value. (Note that for speed and ease of installation, the KC Multi-Ring SmartBox is calibrated to the recommended bolt torque for each pipe size using KC Multi-Ring gaskets, allowing the use of an electric impact wrench for the first 3 passes - a calibrated torque wrench is always used for the final Quality Control pass.) Note: Optimal results are obtained when used in conjunction with KC Multi-Ring reduced surface area low-torque gaskets. 3-4 Copyright 2001 KC Multi-Ring Products, Inc. All rights reserved. Information in this document is sub-

34 Benefits How You Benefit From The KC Sealing System A New Definition Of Leaky Flanged Joints Comparison Of Flanged Joint After Bolt-Up Joining Dissimilar Flange Adapter Types Gasket Stress Across Flange Comparison Of Gasket Fit To High Purity PVDF Flanges Comparison Of Gasket Fit To Schedule 10 Flanges Comparison Of Gasket Fit To New ANSI Flanges Comparison Of Gasket Fit To Old ANSI Flanges Torque Used to Seal Common Flange Styles a Bolt Strain Vs. Gasket Area Force Pulling Joint 150 PSI Force Pulling Joint 232 PSI Force Pulling Joint 150 PSI The Effects Of Single Pass Tightening Example Of Bolt Talk When Tightening Up Flanges

35 How You Benefit From The KC Sealing System KC Multi-Ring Gasket Design Evenly distributes clamping force around entire flange face Reduces/eliminates flange distortion Requires as little as 50% bolt torque as conventional designs Engineered to fit each different pipe/flange style Available in these styles: PVDF Universal New ANSI PVDF ring - BCF/IR flange adapters Old ANSI PVDF ring - socket fusion flange adapters FRP Ducting Schedule 10 Polypro & others contact factory Only one torque value required for same size flange in PVDF, Schedule 10, and New ANSI styles in like material Gasket styles can be cut and molded from any material: Expanded PTFE Expanded PTFE (densified) KRYSTLE-CLEAR FPM (Fluorine Rubber) EPDM FKM Other sheet or roll material AC Backing Flanges Engineered to direct the clamping force towards the pipe ID, not the flange adapter OD Provides a positive seal at the inner ring on a KC Multi-Ring gasket or any other gasket Minimizes gasket surface area contacted by medium (Contamination from gasket is proportional to gasket surface area) Reduces the cavity at flanged joints Available for plastic piping Thermoplastic coating is more resilient and less brittle than PVDF When an AC flange is dropped, the coating dents rather than shatters Dents can be smoothed out in the field with a heat gun Independent Finite Element Analysis confirms KC Multi-Ring, Inc. s lab results 4-1

36 A New Definition of Leaky Flanged Joints For some, the test of whether a flanged joint is leaking is as simple as whether you are tripping over a bucket on the floor. If not, everything is OK, you can forget about the joint and move on to the next one. (We call this the bucket test). On the surface, one might think that the bucket test is fine for all applications. However, the bucket test looks only at what is happening at the flange OD and ignores what is happening between the pipe ID and flange OD. At a minimum, the bucket test is not appropriate for ultrapure water applications. A number of problems can arise if the joint is sealed at the flange OD and not the pipe ID: 1. The flange adapters are dished. Over time, thermoplastic pipe takes on a thermal set, even at ambient temperatures. This effect is accelerated at elevated temperatures. 2. Both sides of the gasket are exposed to the water. It is widely held that contamination is directly proportional to the surface area of the gasket exposed to the water. 3. Both flange faces are wetted. Water is trapped in this dead spot, providing an ideal breeding ground for bugs to grow. This trapped water and any bugs it contains may be flushed into the system when valves close abruptly and water hammer occurs. 4. The pipe run is unevenly stressed at each flanged joint. 5. The hydraulic forces, which the joints must overcome, greatly increase. 6. It may be difficult to re-seal the joint once it is taken apart. The figure below shows the flange which KC Multi-Ring Products, Inc. uses to evaluate its designs. We drill through the first annular groove (measuring from the ID) to a depth of about 1/2 of the flange thickness. We then cross-drill through the flange wall so that we create a path from the flange face to the outside. Cross-section of a flanged joint with test holes drilled into the first annular grooves of serrated face PVDF flange adapters. Note that we drilled test ports in both flange adapters to ensure that the gasket did not act like a shuttle valve. Finally, we defined a joint as leaky if any water came out of the test ports, rather than whether any water dripped from the joint OD. You may be wondering whether we still needed our bucket right at our test fixture to catch what was leaking through these test ports? 4 No, but only for KC Multi-Ring Products, Inc. s patented reduced surface area lowtorque gaskets installed between KC Multi-Ring Products, Inc. s patented AC backing flanges! Yes, for all other combinations of gaskets and backing flanges we tested for UPW applications. 4-2

37 Comparison of Flanged Joint After Bolt-Up Figure 1-80 ft-lbs of torque on conventional flat backing ring and 1/8 expanded PTFE 100% contact full face gasket. 225mm SYGEF pipe. Figure 2-56 ft-lbs of torque on AC backing flange and 1/8 expanded PTFE KC Multi-Ring low-torque gasket. 225mm SYGEF pipe. The benefits of KC Multi-Ring Products, Inc. s patented AC flange rings are clearly demonstrated in the two figures above. In figure 1, the flat backing rings rotate approximately 2 thereby single-point loading the outside edge of the flange adapter. At the outside edge, the gasket is compressed to ; at the pipe ID, the gasket is only compressed to Contrast this with the relatively even gasket compression between the pipe ID and outside edge of the flange adapter with the AC flange ring, at only 70% of the torque as used with the flat backing ring. Conventional flat backing ring 1. Seals at the outside edge of the flange adapter. 2. Creates a concave flange adapter face after bolt-up and during subsequent system operation. 3. Over time, thermoplastic flange adapters take on a concave thermal set, even at ambient temperatures. Effect is accelerated by elevated temperatures. Difficult to re-seal if the joint is ever taken apart. 4. Both flange faces and both sides of gasket exposed to medium, providing an excellent breeding ground for contamination. 5. Independent Finite Element Analysis confirms higher stress on pipe when joints are installed with conventional flat backing rings. 6. As additional torque is applied to the fasteners, the sealing point does not change since the backing rings rotate around the outside edge of the flange adapter. KC Multi-Ring AC backing flange 1. Seals closer to the pipe ID. 2. Flange adapter face is square after bolt-up and during subsequent system operation. 3. No concave flange adapters. KC Multi-Ring Products, Inc. s flange ring design can even bring a concave flange adapter back square. 4. Flange face and gasket area exposed to medium are substantially reduced. 5. Independent Finite Element Analysis confirms lower stress on pipe when joints are installed with KC Multi-Ring AC flange backing rings. 6. As additional torque is applied to the fasteners, the rotation of the flange ring swings the center line of force toward the ID of the pipe to obtain a better seal. 4-3

38 Joining DisSimilar Flange Adapter Types Figure 3 - Butt-weld mated to socket fusion flange adapter; joined with conventional flat backing rings. Illustrated above are the effects of joining dissimilar OD flange adapter types. In both cases, a larger OD butt-weld flange adapter is joined to a smaller OD socket fusion flange adapter. Figure 3 shows a joint installed with conventional flat backing rings. Figure 4 shows a joint installed with KC Multi-Ring AC flange rings. As torque is applied to the fasteners of conventional flat backing rings, the backing rings rotate approximately 2 and the bolts move to the outside of the bolt holes, thereby single-point loading the outside edge of each flange adapter. The outside edge of the smaller OD socket fusion flange adapter acts as a knife edge as the larger OD buttweld flange adapter is bent over. Both flange adapters become concave, with the bulk of the sealing taking place only at the outside edge of the smaller flange. Both flange faces and both sides of the gasket are exposed to the medium, providing an ideal breeding ground for contamination. Figure 4 - Butt-weld mated to socket fusion flange adapter; joined with KC Multi-Ring AC backing flanges. The same effects can be observed when pipe spools are joined to valves and pumps. It is quite common for the OD of the flange face on the valve or pump body to differ from the OD of the flange adapter. The performance of flanges joined with the KC Multi-Ring backing flanges is clearly superior. The contact points on flange adapters are the inner radius of the backing flanges, not on the outside edge as with the flat rings. This center line of the force applied to the joint is practically parallel to the pipe. Any rotation resulting from greater bolt load swings the force towards the pipe ID, resulting in a better seal. Flange faces are kept square, not concave, and sealing takes place near the pipe ID. Wetted surfaces and breeding ground for contamination are minimized. Finally, medium impurities resulting from flanged joints are minimized and gasket wetted surfaces are reduced using the KC Multi-Ring low-torque design

39 Gasket Stress Across Flange 6 150# Fiberglass Reinforced Plastic Stress of Gasket in PSI Bolt Hole to Bolt Hole Minimum Stress to Seal - 1/8 Expanded PTFE Full Face KC Multi-Ring Design In order to seal a flanged joint, the gasket installed must be adequately stressed by the joint. The chart above presents the dramatic difference in gasket stress on a full face gasket and a KC Multi-Ring gasket installed in a 6 150# fiberglass reinforced plastic flange. Gasket stress was measured at the centerline of two adjacent bolt holes and 13 equal points between bolt hole centerlines. The top line shows the relatively even stress on a 1/8 expanded PTFE KC Multi-Ring gasket as one moves between bolt holes. Note the minor drop in gasket stress at approximately 0.52 away from each bolt hole centerline, with constant gasket stress at other measurement points. The middle line shows the minimum stress required to seal 1/8 expanded PTFE, the material from which both subject gaskets were cut. The bottom line shows the gasket stress on a 1/8 expanded PTFE full face gasket. Note that the stress decreases symmetrically, reaching the minimum stress halfway between bolt holes. At the midway point, gasket stress has diminished to approximately 1/2 of the stress as measured at each bolt hole. Please note that the torque required to stress the full face gasket equal to the stress on the KC Multi-Ring gasket would have caused flange fatigue and failure. 4-5

40 0.25 COMPARISON OF GASKET FIT TO HIGH PURITY PVDF FLANGES (plotted points reflect radial protrusion or cavity) # > 0 = Protrusion into Flow Stream # < 0 = Cavity in Flanges Flange Size - in inches Old ANSI New ANSI Sch. 10 PTFE - PVDF/EPDM KC Multi-Ring Note that the KC Multi-Ring gasket is designed so that the gasket ID matches the flange ID. All other gaskets either act as installed orifice plates (when the gasket protrudes into the flow stream), or create cavities at the joint. Both conditions create dead spots, an ideal breeding ground for micro-contamination. Missing data points for a given style/size combination mean that either that size is not available, or the radial difference in gasket ID to flange ID exceeds +/

41 0.25 COMPARISON OF GASKET FIT TO SCHEDULE 10 FLANGES (plotted points reflect radial protrusion or cavity) # > 0 = Protrusion into Flow Stream # < 0 = Cavity in Flanges Flange Size - in inches Old ANSI New ANSI KC - Schedule10 PTFE/EPDM HP PVDF Note that the KC Multi-Ring gasket is designed so that the gasket ID matches the flange ID. All other gaskets either act as installed orifice plates (when the gasket protrudes into the flow stream), or create cavities at the joint. Missing data points for a given style/size combination mean that either that size is not available, or the radial difference in gasket ID to flange ID exceeds +/

42 0.25 COMPARISON OF GASKET FIT TO NEW ANSI FLANGES (plotted points reflect radial protrusion or cavity) # > 0 = Protrusion into Flow Stream # < 0 = Cavity in Flanges Flange Size - in inches Old ANSI KC - New ANSI Schedule10 PTFE/EPDM HP PVDF Note that the KC Multi-Ring gasket is designed so that the gasket ID matches the flange ID. All other gaskets either act as installed orifice plates (when the gasket protrudes into the flow stream), or create cavities at the joint. Missing data points for a given style/size combination mean that either that size is not available, or the radial difference in gasket ID to flange ID exceeds +/

43 0.25 COMPARISON OF GASKET FIT TO OLD ANSI FLANGES (plotted points reflect radial protrusion or cavity) # > 0 = Protrusion into Flow Stream # < 0 = Cavity in Flanges Flange Size - in inches KC - Old ANSI New ANSI Schedule10 PTFE/EPDM HP PVDF Note that the KC Multi-Ring gasket is designed so that the gasket ID matches the flange ID. All other gaskets either act as installed orifice plates (when the gasket protrudes into the flow stream), or create cavities at the joint. Missing data points for a given style/size combination mean that either that size is not available, or the radial difference in gasket ID to flange ID exceeds +/

44 90 TORQUE USED TO SEAL COMMON FLANGE STYLES Flange Size - in inches New ANSI - Raised Schedule 10 HP PVDF - BCF HP PVDF - Socket KC - New ANSI - Raised KC - Schedule 10 KC - High Purity PVDF 4-9a

45 BOLT STRAIN VS. GASKET AREA Area (sq. inches) Bolt Diameter (in.) Nominal Pipe Size (in.) KC Multi-Ring New ANSI Raised Face Schedule 10 Bolt Size This chart shows the total gasket surface area divided by the number of bolts in ANSI 150# bolt pattern. The data helps explain why 3 and 8 flanges are the toughest to seal with conventional flanges, and how sealing is improved with the reduced surface area KC Mult-Ring gasket design. 4-10

46 2,400 FORCE PULLING JOINT 150 PSI 2,200 2,000 1,800 1,600 1, 400 Force in Pounds 1, 200 1, /8 1/4 3/8 1/2 3/ /4 1 1/ / /2 4 Schedule 10 SYGEF HP Schedule Nominal Pipe Size This chart shows the hydraulic forces that joint bolts must overcome to seal, assuming that sealing occurs at the pipe ID. Since conventional backing flanges seal near the flange OD, effective hydraulic forces (calculated at the actual sealing point) are greater than shown. Force is calculated as pressure x flange ID radius x pi

47 FORCE PULLING JOINT 232 PSI Force in Pounds /8 1/4 3/8 1/2 3/ /4 1 1/ / /2 4 Schedule 10 SYGEF HP Schedule Nominal Pipe Size This chart shows the hydraulic forces that joint bolts must overcome to seal, assuming that sealing occurs at the pipe ID. Since conventional backing flanges seal near the flange OD, effective hydraulic forces (calculated at the actual sealing point) are greater than shown. Force is calculated as pressure x flange ID radius x pi

48 FORCE PULLING JOINT 150 PSI 66,000 60,000 54,000 48,000 42,000 Force in Pounds 36,000 30,000 24,000 18,000 12,000 6,000 Schedule 10 SYGEF HP Schedule Nominal Pipe Size This chart shows the hydraulic forces that joint bolts must overcome to seal, assuming that sealing occurs at the pipe ID. Since conventional backing flanges seal near the flange OD, effective hydraulic forces (calculated at the actual sealing point) are greater than shown. Force is calculated as pressure x flange ID radius x pi

49 THE EFFECTS OF SINGLE PASS TIGHTENING Microstrain Flange Bolt Number This chart shows the variability of compressive force for 20 bolts, all of which are tightened to the same torque following a star pattern. Maximum compressive force is applied at bolts 5, 10, 15 and 20. Minimum force is applied at bolts 1, 6, 11 and 16; the average force for these bolts average only about 1/8 of the maximum. All other bolts average about 1/2 of the maximum. 4-14

50 EXAMPLE OF BOLT TALK WHEN TIGHTENING UP FLANGES Microstrain Flange Bolt Number Pass 1 Pass 2 Pass 3 Pass 4 This chart shows the variability of compressive force for 20 bolts, all of which are tightened to the same torque following a star pattern. Maximum compressive force is applied at bolts 5, 10, 15 and 20. With single-pass tightening, minimum force is applied at bolts 1, 6, 11 and 16; the average force for these bolts average only about 1/8 of the maximum. All other bolts average about 1/2 of the maximum. It is important to note that with multi-pass tightening, the final value for each bolt is higher than with single pass tightening, and the range between the maximum and minimum values is much narrower. The minimum value is about 2/5 of the maximum, and all other bolts average about 7/10 of the maximum. 4-15

51 Installation Instructions Installation Procedure For AC Backing Flange Installation Procedure For UltraPure Gasket Installation Procedure For KC Multi-Ring UltraPure Gasket a Installation Procedure For KC Multi-Ring UltraPure Gasket b Installation Procedure For KC Multi-Ring UltraPure Gasket c Installation Procedure For KC Multi-Ring UltraPure Gasket d Optimum and Minimum Torque Requirements For Flanges With KC Multi-Ring UltraPure Gaskets Optimum and Minimum Torque Requirements For Flanges With KC Multi-Ring UltraPure Gaskets a Optimum and Minimum Torque Requirements For Flanges With KC Multi-Ring UltraPure Gaskets b Optimum and Minimum Torque Requirements For Flanges With KC Multi-Ring UltraPure Gaskets c Installation Procedure For Blind KC Multi-Ring UltraPure Gaskets Fastener Length For ANSI PVDF Flanges (PVDF Bolt Lengths) Fastener Length For ANSI Polypropylene Flanges (Poly Pro PN10)...5-6

52 Installation INSTALLATION PROCEDURE FOR AC BACKING FLANGE 1. Inspect box for damage from shipping. Notify carrier of any damage and make claims as required. 2. After removing the AC Backing Flange from the box, inspect the beveled surface between the AC Backing Flange inside diameter (ID) for any sharp protrusion which could come into contact with the flange adapter. Any sharp edge in this area is cause for rejection. 3. When installation is required, verify that each AC Backing Flange is the proper size, flange type, and coating for the given application. 4. If AC Backing Flange is rejected due to a surface deformation in the above noted area, set aside for return and specify reason for rejection. 5. Slip AC Backing Flange over flange adapter and rotate ring to confirm correct fit and size. Note: Beveled surface on AC Backing Flange faces flange adapter; washers, bolts, and nuts go on flat surface of AC Backing Flange. As with any flange made to ANSI drilling, optimal distribution of clamping force is obtained through the use of heavy-duty washers. 6. Select one AC Backing Flange on each joint for determining the flange tightening sequence, and follow the star pattern for all tightening passes on that joint. 7. Install all AC Backing Flanges using a calibrated torque wrench or a KC Multi-Ring SmartBox. Whenever possible, apply the torque to the nut. All passes are to be made following the tightening sequence described above. For pass 1, torque each nut to 33% of the desired torque value. For pass 2, re-torque each nut to 66% of the desired torque value. For pass 3, re-torque each nut to 100% of the desired torque value. Wait two minutes and re-torque to 100% value. (Note that for speed and ease of installation, the KC Multi-Ring SmartBox is calibrated to the recommended bolt torque for each pipe size using KC Multi-Ring gaskets, allowing the use of an electric impact wrench for the first 3 passes - a calibrated torque wrench is always used for the final Quality Control pass.) Note: Optimal results are obtained when used in conjunction with KC Multi-Ring reduced surface area low-torque gaskets. 5-1

53 INSTALLATION PROCEDURE FOR KC MULTI-RING ULTRAPURE GASKET The gaskets will arrive cleaned and individually packaged in sealed bags. Each bag will be labeled with a part number which will correlate with pipe type(s) and dimension. Gaskets of similar size and type will be aggregated and packaged in a larger sealed bag, typically in groups of ten (10). Installation 1. When installation is required, verify that the gasket is the proper size and flange type. When installing the gasket, installer shall wear appropriate garments to meet the appropriate clean zone protocol in effect at the time. Specifically, clean room gloves are to be worn at all times while handling gaskets. 2. While gasket is in the individually sealed bag, inspect for any surface deformations such as tears, rips, or non-uniform cuts. Any material defect of the inner surface is cause for rejection. 3. If a gasket is rejected due to a surface deformation, place aside for return and specify reason for rejection. 4. Great care should be taken to protect the gasket surface from exposure to oil or other contaminants. 5. Remove gasket from bag. 6. Immediately prior to installing, pay particular attention to the inner surface. Do not wipe the surface with or expose the surface to IPA (Isopropyl Alcohol). 7. Pay particular attention to keeping the gasket and flange adapters on the same axis (that is, geometrically centered). 8. Install all flanges using a calibrated torque wrench. Whenever possible, apply the torque to the nut. Tighten the flanges in a star pattern to the following torque values using progressive 4-pass tightening. Following the star pattern, torque each nut to 33% of the desired torque value. Then re-torque to 66% of the desired torque value. Re-torque to 100% of the desired torque value. Wait two minutes and re-torque to 100% value. 9. Using a clean feeler gauge select a pair of blades that add up to 54 or 55 1/1000 s. If you can get the feeler gauge into the notch then the seal is not certain and you will need to make another pass. If after that it is still not compressed to <54/1000 s then up the force by 2% and make another pass. The use of the feeler gauge to measure compression is the only certain way to measure if the KCMR expanded PTFE gasket is sealed. Note: Optimal results are obtained when KC Multi-Ring gaskets are used in conjunction with KC Multi-Ring AC backing flanges. 5-2a

54 Relying on torque alone does not allow for all the variations that can happen in the field. Torque alone does not measure the force that is applied to the gasket. Variations in nuts and bolts, ability to access the flange fittings, tension due to slight misalignment all compromise being able to rely on torque alone as the measure of gasket compression. Using a feeler gauge on the KCMR Patented notch assures there has been enough force to cause the gasket to seal. A.125 eptfe gasket needs to be compressed to less than.055/1000 s to assure seal. Using the feeler gauge will avoid leaks at hydro-testing which are much harder to seal later. Install procedure for KCMR gasket 5-2b

55 Install procedure for KCMR gasket 5-2c

56 Install procedure for KCMR gasket 5-2d

57 optimum and minimum Torque Requirements for Flanges with KC Multi-Ring UltraPure Gaskets (33% - 66% - 100% values shown in parentheses) pvdf and polypropylene pipe flanges using kc multi-ring backing flanges and zinc-plated sae grade a-307 fasteners, with sae hardened flat washers on both sides; belleville washers can be used with, but do not replace, flat hardened washers Torque (in foot-pounds) Torque (in newton-meters) Bolt Number of SIZE Size Bolts Optimum Torque Minimum Torque 20mm 1/2 4 7 (2/5/7) 5 (2/3/5) 10 (3/6/10) 7 (2/5/7) 25mm 1/2 4 9 (3/6/9) 7 (2/5/7) 12 (4/8/12) 10 (3/6/10) 32mm 1/ (4/8/12) 9 (3/6/9) 16 (5/11/16) 12 (4/8/12) 40mm 1/ (7/13/20) 15 (5/10/15) 27 (9/18/27) 20 (7/14/20) 50mm 1/ (8/16/24) 18 (6/12/18) 33 (11/22/33) 24 (8/16/24) 63mm 5/ (10/20/30) 22 (7/15/22) 41 (14/27/41) 30 (10/20/30) 75mm 5/ (12/23/35) 26 (9/17/26) 47 (16/32/47) 35 (12/23/35) 90mm 5/ (13/27/40) 30 (10/20/30) 54 (18/36/54) 41 (14/27/41) 110mm 5/ (13/25/38) 33 (11/22/33) 52 (17/34/52) 45 (15/30/45) 160mm 3/ (22/44/65) 44 (15/30/44) 88 (29/59/88) 60 (20/40/60) 225mm 3/ (27/53/80) 56 (19/37/56) 108 (36/72/108) 76 (25/51/76) 250mm 7/ (44/87/131) 100 (33/68/100) 178 (59/108/178) 136 (45/90/136) 315mm 7/ (80/160/240) 180 (60/120/180) 326 (108/216/326) 244 (81/162/244) NOTE: For speed and ease of installation, the KC Multi-Ring SmartBox is calibrated to the recommended bolt torque for each pipe size, allowing the use of an electric impact wrench for the first 3 passes (a calibrated torque wrench is always used for the final Quality Control pass). 5-3

58 optimum and minimum Torque Requirements for Flanges with KC Multi-Ring UltraPure Gaskets (33% - 66% - 100% values shown in parentheses) pvdf and polypropylene pipe flanges using kc multi-ring backing flanges and zinc-plated sae grade a-307 fasteners, with sae hardened flat washers on both sides; belleville washers can be used with, but do not replace, flat hardened washers Torque (in foot-pounds) Torque (in newton-meters) Bolt Number of SIZE Size Bolts Optimum Torque Minimum Torque 355mm (104/208/311) 232 (77/155/232) 422 (141/281/1422) 315 (105/210/315) 400mm (93/187/280) 209 (70/139/209) 380 (127/253/380) 284 (95/189/284) 450mm 1-1/ (105/210/315) 235 (78/157/235) 428 (143/285/428) 319 (106/213/319) 500mm 1-1/ (99/198/297) 222 (74/148/222) 403 (134/269/403) 301 (100/200/301) NOTE: For speed and ease of installation, the KC Multi-Ring SmartBox is calibrated to the recommended bolt torque for each pipe size, allowing the use of an electric impact wrench for the first 3 passes (a calibrated torque wrench is always used for the final Quality Control pass). 5-3a

59 optimum and minimum Torque Requirements for stainless steel Flanges with KC Multi-Ring schedule 10 UltraPure Gaskets (33% - 66% - 100% values shown in parentheses) confirm flange faces are transversely parallel to one another before installing gasket. use zinc or cadmium plated fasteners with sae hardened flat washers on both sides; belleville washers can be used with, but do not replace, flat hardened washers. Torque (in foot-pounds) Torque (in newton-meters) Bolt Number of SIZE Size Bolts Optimum Torque Minimum Torque 1/2 1/ (3/7/10) 6 (2/4/6) 14 (5/9/14) 8 (3/5/8) 3/4 1/ (5/9/14) 9 (3/6/9) 19 (6/13/19) 12 (4/8/12) 1 1/ (6/13/19) 12 (4/8/12) 26 (9/17/26) 16 (5/11/16) 1-1/4 1/ (9/19/28) 18 (6/12/18) 38 (13/25/38) 25 (8/16/25) 1-1/2 1/ (13/25/38) 24 (8/16/24) 52 (17/34/52) 33 (11/22/33) 2 5/ (25/50/76) 49 (16/32/49) 103 (34/68/103) 67 (22/44/67) 2-1/2 5/ (24/58/88) 57 (19/38/57) 120 (40/79/120) 78 (26/51/78) 3 5/ (43/86/130) 84 (28/55/84) 177 (58/117/177) 114 (38/75/114) 4 5/ (30/61/92) 60 (20/40/60) 125 (41/83/125) 82 (27/54/82) 6 3/ (57/115/174) 112 (37/74/112) 237 (78/156/237) 152 (50/101/152) 8 3/ (78/155/235) 152 (50/100/152) 320 (106/211/320) 207 (68/136/207) 10 7/ (74/147/223) 144 (48/95/144) 303 (100/200/303) 196 (65/129/196) 12 7/ (98/196/297) 192 (63/127/192) 404 (133/267/404) 261 (86/172/261) NOTE: Allow 2 minutes for initial creep and relaxation to occur the re-torque to final toque using a calibrated torque wrench for the final quality control pass. Confirm compressed gasket is maximum.055 inches installed thickness between each bolt using the KC Multi-Ring patented gauge notch. It is the installer s responsibility to confirm flanges and fasteners will handle the torque values. 5-3b

60 optimum and minimum Torque Requirements for stainless steel Flanges with KC Multi-Ring schedule 10 UltraPure Gaskets (33% - 66% - 100% values shown in parentheses) confirm flange faces are transversely parallel to one another before installing gasket. use zinc or cadmium plated fasteners with sae hardened flat washers on both sides; belleville washers can be used with, but do not replace, flat hardened washers. Torque (in foot-pounds) Torque (in newton-meters) Bolt Number of SIZE Size Bolts Optimum Torque Minimum Torque (122/244/370) 239 (79/158/239) 503 (166/332/503) 325 (107/215/325) (116/232/351) 227 (75/150/227) 477 (158/315/477) 309 (102/204/309) / (177/354/536) 347 (115/229/347) 729 (241/481/729) 472 (156/312/472) / (156/312/473) 306 (101/202/306) 643 (212/425/643) 416 (137/275/416) NOTE: Allow 2 minutes for initial creep and relaxation to occur the re-torque to final toque using a calibrated torque wrench for the final quality control pass. Confirm compressed gasket is maximum.055 inches installed thickness between each bolt using the KC Multi-Ring patented gauge notch. It is the installer s responsibility to confirm flanges and fasteners will handle the torque values. 5-3c

61 INSTALLATION PROCEDURE FOR BLIND KC MULTI-RING ULTRAPURE GASKETS The gaskets will arrive cleaned and individually packaged in sealed bags. Each bag will be labeled with a part number which will correlate with pipe type(s) and dimension. Gaskets of similar size and type will be aggregated and packaged in a larger sealed bag, typically in groups of ten (10). Installation 1. When installation is required, verify that the gasket is the proper size and flange type. When installing the gasket, installer shall wear appropriate garments to meet the appropriate clean zone protocol in effect at the time. Specifically, clean room gloves are to be worn at all times while handling gaskets. 2. While gasket is in the individually sealed bag, inspect for any surface deformations such as tears, rips, or non-uniform cuts. Any material defect of the inner surface is cause for rejection. 3. If a gasket is rejected due to a surface deformation, place aside for return and specify reason for rejection. 4. Great care should be taken to protect the gasket surface from exposure to oil or other contaminants. 5. Remove gasket from bag. 6. Immediately prior to installing, pay particular attention to the inner surface. Do not wipe the surface with or expose the surface to IPA (Isopropyl Alcohol). 7. Pay particular attention to keeping the gasket and flange adapters on the same axis (that is, geometrically centered) Install all flanges using a calibrated torque wrench, or a KC Multi-Ring SmartBox. Whenever possible, apply the torque to the nut. Tighten the flanges in a star pattern to the following torque values using progressive 4-pass tightening. (Note that the pipe size and tightening sequence is cast into the face of the AC Backing Flange.) Following the star pattern, torque each nut to 33% of the desired torque value. Then re-torque to 66% of the desired torque value. Re-torque to 100% of the desired torque value. Wait two minutes and re-torque to 100% value. (Note for speed and ease of installation, the KC Multi-Ring SmartBox is calibrated to the recommended bolt torque for each pipe size, allowing the use of an electric impact wrench for the first 3 passes - a calibrated torque wrench is always used for the final Quality Control pass.) Special Note: If the gasket is to be installed on a plastic blind flange, install a KC Multi-Ring AC backing flange behind the blind flange; this will prevent dishing of the plastic blind flange and subsequent leakage. 5-4

62 FASTENER LENGTH FOR ANSI PVDF FLANGES (PVDF Bolt Lengths) Flange to Flange Flange to Valve DIN ANSI Bolt Bolt Bolt SAE Gasket Flange Face Standard Duty Heavy Duty Standard Duty Heavy Duty Hole Diameter Size Washer Thickness Thickness Bolt Length Bolt Length Bolt Length Bolt Length mm inch # inch inch Thickness inch inch inch inch inch inch inch 20mm 1/ mm 3/ mm mm 1 ¼ mm 1 ½ mm mm 2 ½ mm mm mm mm 5 ½ mm mm mm mm mm mm mm mm

63 FASTENER LENGTH FOR ANSI POLYPROPYLENE FLANGES (Poly Pro PN10) DIN ANSI Bolt Bolt Bolt SAE Gasket Flange Face Flange Flange Hole Diameter Size Washer Thickness Thickness to Flange to Flange mm inch inch inch inch Thickness (inch) inch inch inch inch 20mm 1/ mm 3/ mm mm 1 ½ mm mm mm mm mm mm mm mm mm mm mm

64 Conversions Sample Specification Sheet Conversions