DECLARATION

I hereby declare that I have completed my industrial training in vendor development

department at Talbros Automotive Component Ltd (Gasket division) from Jan 16, 2019 to
May 23, 2017 under the guidance of Mr. Bhaskar Kumar(Purchase Head). I declare that I
have worked with full dedication during this training and my learning outcomes fulfil the
requirements for the award of degree of B. Tech (ME), university institute of engineering and
technology,Maharshi dayanad university,rohatk.

…………………….

Aman malhotra

Reg. No. 11615630

ACKNOWLEDGEMENT

Success is the cause for co-operation and guidance from seniors. It is one of the fortunate
moments of my life that I have get an opportunity to express my gratitude to the almighty and
all the people whose co-operation has been indispensable in compiling this project.
Motivation and co-operation are the two main pillars on which the success of any projects
relies we would like to thank core guides of our project Mr. BHASKAR KUMAR who
guided me at each and every stage of the project.
I deeply appreciate the assistance provided by my Parents at every moment. Last but not
least, my special thanks to all the people I have contacted who has given me their valuable
time and information throughout the project work
Preface

It is said that, “Experience makes man perfect”. But the question from which things does this
experience come?
Obviously from practical knowledge. So practical training is also important aspect in
management course. There is vast difference between practical knowledge and actual
practical implications.”
Practical knowledge helps in developing intellectual state of mind and increasing conceptual
and analytical skill of the person. In the industrial environment,a student can clear their
doubts about various technical terms that it had during lectures in the classroom.
Throughout my training session, I tried to collect information regarding the project. Any
valuable suggestions
would be gratefully acknowledged.
Chapter1- About Organization

1.1 COMPANY PROFILE

Talbros Automotive Components Ltd., the flagship manufacturing company of the Group
was established in the year 1956 to manufacture Automotive & Industrial Gaskets in
collaboration with Coopers Payen of UK.

Today, after 58 successful years, Talbros stands proud and tall as a mother brand of Gaskets
& Heat Shields, Forgings, Suspension Systems & Modules, Anti Vibration components and
Hoses.

Talbros Group has strong partnerships formed with global giants. Notable among the joint
venture partners are Nippon Leakless Corporation- Japan, MagnetiMarelli- Italy, Marugo
Rubber- Japan and technology partners are Sanwa Packaging – Japan and Interface Solutions
– USA.

While our symbiotic relationship with our Global partners have kept us abreast with
innovations within the field, our long and fruitful association with them bears witness to the
trust and solidarity that Talbros name is synonymous with.

Our Research & Development Centre showcase our design capabilities including endurance,
static and simulated environment testing. Today, our manufacturing prowess spans over 5
business and 8 facilities.

The largest OEMs like Ashok Leyland, Bajaj Auto, Cummins Group, Eicher India, Escorts
Group, Force Motors, General Motors, Hero Honda, Honda, Hyundai, John Deere, Mahindra
& Mahindra, Maruti Suzuki, Suzuki, TAFE, Tata Motors, Tata Cummins, Simpsons and
international corporates like Carraro, DANA, KMP Brand, Maxi Force, GKN Driveline are
our proud customers.

The Group companies are TS 16949, ISO 14001 and OHSAS 18001 certified. Our team takes
the quest for quality very seriously. For every piece that is manufactured, quality standards
are strictly adhered to and industry benchmarks often set.

Our unrelenting quest for perfection extends to the supply chain and to every person
responsible for extending quality service to the customer.
Talbros is where it is today due to the excellence of its product offerings, its commitment to
quality, attention to detail and, primarily, due to its incredible workforce. Our people-friendly
and professional approach towards human resource development is responsible for our
remarkably low attrition rate.

Constant upgradation of skills at training programmes in India and abroad and an exemplary
work culture has made every member of our team geared for new challenges. Both employee
and customer satisfaction are of extreme importance to us.

Talbros Group portfolio also includes Mercedes Benz dealership for passenger cars.

Talbros, where it is today is due to the excellence garanti e vadeliesapof its product offerings,
commitment to quality, attention to detail and professional approach.

We, today can design, develop and manufacture products as per customer requirements
competitively.

1.2 VISION

“Talbros group’s endeavor is to be a significant global player in the auto industry by being a
brand of choice for all our customers and continuously enhancing employee satisfaction and
stakeholder value.”

1.3 MISSION

Gasket:

“To be committed to foster and uphold our leadership in providing comprehensive sealing
solutions at economical price to our customers across all manufacturing sectors, while
sustaining a rewarding work environment for our supreme assets, our employees, nurtured by
strong brand image & pioneering narrations.”
1.4 BRANCHES OF THE COMPANY

 TALBROS AUTOMOTIVE COMPONENTS LTD. – GASKET DIVISION

 TALBROS AUTOMOTIVE COMPONENTS LTD. – FORGING DIVISION

 MAGNETI MARELLI TALBROS CHASSIS SYSTEMS PVT. LTD.

 TALBROS MARUGO RUBBER PVT. LTD.

 NIPPON LEAKLESS TALBROS PVT. LTD.

1.5 CERTIFICATIONS
 Chapter2 Introduction to Gaskets

GASKET

A gasket is a mechanical seal which fills the space between two or more mating surfaces, generally
to prevent leakage from or into the joined objects while under compression.

Gaskets allow for "less-than-perfect" mating

surfaces on machine parts where they can fill
irregularities. Gaskets are commonly produced by
cutting from sheet materials.

Gaskets for specific applications, such as high

pressure steam systems, may contain asbestos.
However, due to health hazards associated with
asbestos exposure, non-asbestos gasket materials
are used when practical.[1]

It is usually desirable that the gasket be made from

a material that is to some degree yielding such that
it is able to deform and tightly fill the space it is
designed for, including any slight irregularities. A
few gaskets require an application of sealant
directly to the gasket surface to function properly.

Some (piping) gaskets are made entirely of metal

and rely on a seating surface to accomplish the seal;
the metal's own spring characteristics are utilized
(up to but not passing σy, the material's yield
strength). This is typical of some "ring joints" (RTJ)
or some other metal gasket systems. These joints
are known as R-con and E-con compressive type
joints.
 TYPES OF GASKET

The most common types of gaskets are:

 Gaskets used in piping (flange gaskets)
 Gaskets used in vehicles (cars, boats, planes, trains)
 Gaskets with certain material properties (cork, rubber paper etc.)
 Gaskets used for a particular function (for pressure, temperature, or chemical resistance)
 Bespoke or custom made gaskets

Gasket Types and Uses

Gaskets can be classified in many different ways, for example: by material, by function, or
by application. A gasket is basically a part cut from a (usually) flexible material, which sits in
between two other surfaces. Gaskets are typically manufactured from soft materials (such as
rubber); and one of the most common uses is for sealing pipes to prevent the leakage of liquids.
Gaskets also have certain other common applications, such as anti vibration and mounting.

Why Gaskets are used?

A leak from the flange joint can be disastrous. A flange leak results in loss of product and
energy. No plant operator wants leaking of toxic or hazardous material that can harm human and
environment. The gasket can help in achieving reliable sealing to prevent the leak from the
flange joints.

Types of Gaskets to be used in given fluid service is depends on the parameters such as

 Temperature – Gasket material must withstand entire design temperature range of the
fluid it handles.
 Pressure – Gasket material must withstand entire design pressure range of the fluid it
handles.
  Corrosion resistance – Gasket material should not corrode when it comes in contact with
the fluid it handles or by the environmental exposure.
 Types of fluid – Gasket material should be capable of dealing with different type of fluids
if installed in line that handles more than one types of fluids.
 Robustness – The gasket must be capable of withstanding all movement that may occur
due to change in temperature and pressure.
 Availability – Gasket should be easily
 Cost – Cheap and unreliable gasket should not be used at the same time it should not be
costly.

Gasket Types by Material

Gaskets will inherit the properties of the materials from which they are manufactured. Gasket
materials are used because of their resistance to certain chemicals (such as acids), or properties
of being capable of withstanding extreme temperatures or pressures.
Common types of gaskets include:

Rubber Gaskets:-Rubber is a soft gasket material. A wide range of elastomers can be

used, such as neoprene, nitrile, EPDMand natural rubber. Rubber gaskets are used in a wide
range of applications such as pipe gaskets, heat exchangers, and manways.

Non-Asbestos Gaskets:- Non-asbestos gaskets are manufactured from a compressed

fibre with an elastomer binding; and are used in many applications such as acid, steam, oil and
water.

Cork Gaskets:- Natural cork combined with elastomer bindings giving high flexibility and
compression. These gaskets are widely used in applications involving oil, fuel and solvents.

Types of Gasket Material

 Non-metallic
 Metallic Gaskets
  Composite Gaskets

Non-metallic
These can be made from CNAF (Compresses non-asbestos fibre), PTFE,
Rubber, Teflon or Graphite. Non-metallic gaskets can compress easily with low tension bolting.
They’re generally used for low pressure applications and low temperatures. One exception is
graphite gaskets, which can be used for temperatures as high as 460 degrees centigrade.
Rubber and elastomer gaskets are not used for pipelines used to transport hydrocarbons

Metallic Gaskets
Metal is used for ring type joints in high-pressure applications, such as
oil and gas supply production. RTJs are also used on valves and pipework, assemblies in
refineries and other process industries. They seal by an initial line contact or a wedging action as
the compressive forces are applied. Metal ring type gaskets are available with oval and octagonal
cross sections. Octagonal include the BX type designed to seal pressure up to 20,000 psi, in
accordance with API 6A pressure ratings.

Composite Gaskets
Composite gaskets are a combination of metal and non-metal
material based on service requirement. Spiral wound, Metal Jacketed, and Kamprofile gasket are
well known in composite gasket category. They’re used in a wide range of pressure and
temperature services.

Composite gaskets are cost effective as compared to metal gaskets, but careful handling is
required. Composite gaskets are used on raised face, male-female, and tongue-and-groove
flanges.
PRESS MACHINE

Press machine is a metal forming machine tool. Which is designed to form or cut metal by
applying mechanical force or pressure.

With the help of press machine, you can form a metal in any desired shape without removal of
chips. The presses are exclusively intended for mass production work.

Types of Press Machine

The classification of different types of press machine are given below:

1. Classification based on the source of power:

1. Hand press or ball press or fly press
2. Power Press
2. Classification based on the design of frame:
1. Gap
2. Inclinable
3. Adjustable
4. Horn
5. Straight side
6. Pillar
Power Press:

This is widely used types of press machine in the workshop. The constructional feature of a
power press is almost similar to the hand press, the only difference being, the ram instead of
driven by hand is driven by power. The power press is characterized as mechanical or hydraulic
according to the type of working mechanism used to transmit power to the ram.

The figure illustrates a power press driven by a crank and connecting rod mechanism. The punch
is fitted on the end of the ram and the die is attached on the bolster plate. The flywheel mounted
at the end of the crankshaft stores up the energy for maintaining a constant downward speed of
the ram when the sheet metal is pressed between the punch and the die.

Gap Press:

The gap press illustrated in the figure has a gap like opening in the frame for feeding the sheet
metal from one side of the press. The frame is attached with the base and provides a rigid
construction.

Inclined Press:

The inclined press illustrated in the figure is the most common type of press used in industry.
The identifying characteristic of the inclined press is its ability to tilt back on its base, permitting
the scrap or finished products to be discharged from the die by gravity without the aid of any
type of handling mechanism. The press is not so rigid as a gap press due to its construction.

Adjustable bed Press:

The adjustable bed press illustrated in the figure has the mechanical arrangement for raising or
lowering the table on which the die is fitted. This enables the setting of different sizes of work
and dies on the machine. The press is not so rigid as the other types.

Horn Press:

The horn press illustrated in the figure. It has a cylindrical horn like projection from the machine
frame, which serves as the die support. The horns may be interchanged for the different sizes of
 work. The press is intended for the cylindrical workpiece.

Straight Side Press:

The straight side press illustrated in the figure. This press machine has two vertical rigid frames.
These are mounted on two sides of the base which are intended for absorbing critical load
exerted by the ram. The machine is suitable for heavy work, but due to the presence of side
frames, the sheet metal cannot be fed from the side.

Pillar Press:

The pillar press illustrated in the figure. It is a hydraulic press having four pillars mounted on the
base. The pillars support and guide the ram.

GASKET MANUFACTURING
There are many kind of procedure for different gasket. some of their example are as follows:-

NON METALLIC GASKET:-

Fiber gaskets are made by first preparing the material, which is made through a process
similar to papermaking. Strands of fiber are spread out and saturated with resin, which is then
dries to form sheets that can be easily cut to shape. These sheets are loaded with blends of
glass, graphite, PTFE, and other synthetic filaments; the exact mix ratio of which is decided
upon by the manufacturer so that the material accommodates a pre-determined fluid medium.
Here, special blends of rubber and Aramid act as a structural framework for these strands.
They bind together to form long sheets, which are then die stamped into synthetic fiber
gaskets, and are tailored to fit any possible sealing application. However, this process varies
from manufacturer to manufacturer. But, in any case, the binding agent used is the most
critical element in the manufacturing process, as it is this material that binds the toughen ed
filaments in place.
 Which materials are used to build a synthetic fiber gasket?
Synthetic fibers are man-made materials like plastic and glass-based filaments that are built with
a toughened molecular backbone. A long list of such synthetic materials can be used to build
synthetic fiber gaskets. Different fiber types are used to produce gaskets with different strengths,
temperature ratings, and compressibility. These range from cellulose and vegetable fibers to
stronger materials like Aramid. In case of the requirement of additional compressibility, cork or
rubber binders are added. While rubber is a natural product, the rubber used in synthetic fiber
gaskets is a synthetic version. This kind of rubber functions over a wider temperature range and
is lesser vulnerable to damage by UV light. The most commonly used rubber types in such
gaskets include neoprene, nitrile-butadiene rubber (NBR), styrene-butadiene rubber (SPR), and
EPDM rubber. Another option to build synthetic fiber gaskets is of vulcanizing cellulose fiber
materials to make paper-like materials that are both sturdy and lightweight.

Some examples of Non-Metallic Gaskets materials are:

 Biaxially Orientated (Filled) PTFE

 Sheet
 PTFE Joint Sealant
 PTFE Envelope Gaskets
 Flexible Graphite Sheet
 Mica Sheet
 Ceramic Fiber
 Elastomeric and Fiber Sheet
 Compressed Non-Asbestos Sheet
 Expanded PTFE Sheet
 Glass-Filled / Reprocessed
 PTFE Sheet

What is a Fiber Gasket?

  Fiber gasket material is made through a process similar to papermaking. Strands of fiber
are spread out and impregnated with a resin material. This dries to form sheets that are
easily cut to shape.
 Many different type fibers are used to produce gaskets with differing strength,
compressibility and temperature ratings. These range from vegetable fiber and cellulose
to more exotic materials like aramid, (a strong, heat resistant synthetic fiber.)
 When additional compressibility is needed cork or a rubber binder (often NBR) is added.
Alternatively, cellulose fiber material can be vulcanized to make a paper-like material
that’s both hard and lightweight. When this has electrical insulating properties it’s known
as “fish paper.”
 Possibly the oldest type of gasket still in use is the vegetable fiber or “Detroiter” gasket.
This is made from vegetable fibers impregnated with a glue-glycerine compound. It
remains a popular choice in some applications.

Fiber Gasket Properties and Applications

 Fiber material makes gaskets with high tensile strength, (so they’ll resist internal
pressure,) and an upper temperature limit of 250 – 350°F. They have excellent resistance
to chemicals, particularly oils, so are used in many industrial situations, especially
chemical and petroleum product manufacturing.

WHAT IS PTFE GASKET?

PTFE GASKETS
Polytetrafluoroethylene (PTFE) is a synthetic fluoropolymer of tetrafluoroethylene that has
numerous applications. It is also known by the common trade name Teflon

Polytetrafluoroethylene (PTFE) Gasketing is a material with unique chemical resistance

and physical properties. PTFE is chemically inert to most chemicals, with the exception
of molten alkali metals and free fluorine and can withstand a wide temperature
range. PTFE also has excellent anti-stick, dielectric and impact resistance properties.

However, most PTFE gaskets are subject to cold flow or creep relaxation under
compression, which means that gaskets lose thickness, expand in width and length under
applied loads. Creep results in the loss of bolt load and ultimately gasket stress in an
application. And frequently requires additional efforts to regain that lost stress in the field,
which results in increased maintenance costs. Generally, initial seating stress decreases

significantly in the first 4 to 24 hours after installation. Also creep increases

as temperatures increase.

While the property of creep is inherent in this material, the degree of creep in the PTFE
material differs significantly amongst the three (3) largest types of PTFE gaskets; virgin,
filled, and expanded. There are other, less common, PTFE variations commercially
available such as envelope, microcellular, and filled biaxial sheets.

Virgin PTFE:
Virgin PTFE gaskets are made from unaltered PTFE, which preserves the full
chemical compatibility of PTFE but has the inherent high cold flow characteristic
of PTFE. Virgin PTFE provides the basis for improvement of creep relaxation for
other PTFE variations. As a result, this product is generally used in low

temperature non-critical applications.

Filled PTFE:
With the addition of a filler material to virgin PTFE, filled PTFE gaskets reduce the
cold flow; thereby improving the creep relaxation performance. The fillers act as
“speed bumps” slowing the cold flow. However, the addition of a filler reduces the
range of media for which the gasket may be suitable. For example, the addition of
Silica or Barium Sulfate filler would limit the use of the gasket to either acid or
caustic service. Multiple fillers are available to ensure the product is chemical
compatible for a particular application.
The most common filler materials for PTFE gaskets are:
• Silica
• Glass
• Fibers
• Carbon
• Aluminum
• Oxide
• Barium
• Sulfate
• Bronze

Expanded PTFE (ePTFE)

Cold flow is most effectively reduced in expanded PTFE gaskets (ePTFE) by
physically altering the PTFE microstructure. Because no fillers are used, the
complete chemical compatibility of the virgin PTFE is retained.
The ePTFE microstructure is a network of interconnected nodes and fibrils that
increases the tensile strength of the material, decreases the density of the material
and increases the compressibility of the material. Because of the high
compressibility, ePTFE gaskets conform well to surface irregularities. Unlike virgin
and filled PTFE gaskets, ePTFE materials are more easily applied in glass-lined
steel, fragile plastic flanges and other fragile flanges. In addition, ePTFE is
available in sheet, tape or cord (joint sealant) form. The tape and cord forms are

solid form-in-place products.

RUBBER GASKET:-With more than 150 years of experience at the top of the rubber game, you
can rest assured that Rubber Company knows a thing or two about this wonderfully flexible
material. So we thought we’d spell out some of the most widely used phrases associated with one
of most popular gasket: rubber gaskets. As with most industries, the rubber manufacturing world
is festooned with acronyms, jargon and peculiar phrases that we realise can be mighty confusing
 when you’re trying to specify your rubber gasket requirements. Here is a quick guide to some
frequently recurring terms you’re likely to hear.

Rubber gasket spelled out

Gasket – A deformable material clamped between two surfaces so as to prevent loss of material or
pressure and to create a seal. A static (stationary) sealing device used to retain fluids under pressure or
to seal out foreign matter when a deformable material is sandwiched and compressed between two
mating surfaces. Axial Seal – A seal, like a face seal, in which a gasket is squeezed across the top and
the bottom of its cross-section, perpendicular to its axis. If the seal ring were to be placed flat upon a
desktop, the seal compression would occur between the top and bottom of the seal. Static Seal – A
gasket type application in which the seal is contained within two non-moving gland walls. Except for
pulsates caused by cycle pressure, this ensures that the rubber does not move in its environment and
there is no relative movement between the housing surfaces. K-Factor – Heat is measured in British
Thermal Units (BTUs). One BTU is the amount of heat needed to raise the temperature of one pound
of water by one degree Fahrenheit. Thermal conductivity, also known as k-factor, is the measure of a
material’s ability to transfer heat. Energisation – The method by which a seal will engage with its
housing or moving parts. This can be done either by designing an interference fit, such that the
elasticity of the seal provides a constant force against its housing. Or by ensuring that the application of
pressure causes the seal to swell and create an increasingly tighter sealing effect. Tensile strength –
The strength or tensile stress of a material when stretched to breaking point. This is measured in various
units, such as Psi and MPa, and is expressed as a force per unit area. A standard dumbbell type test
piece of known cross sectional area is stretched until it breaks. The force required to do so is then
recorded and expressed as force per unit area.
The manufacturing processes behind our rubber gaskets

 TACL has a dedicated Gasket Manufacturing facility that not only gives us the flexibility to
execute a wide range of cutting and punching processes and materials, but also allows us to
produce a huge variety of products in small to medium volume for many different industries.
Here’s our guide to the various stages of our gasket manufacturing process works.

Gasket Punching
Gasket Punching is a traditional process established in the 1800s whereby a Rule Forme (a
special steel strip bent into the desired shape with the bottom edge sharpened into a blade) is
forced through a sheet of gasket or shim material and slightly into a sacrificial cutting board
below, by means of a hydraulic or power press. The resulting shape contained inside the cutter is
the finished gasket or shim. Originally used widely in the shoe industry, these Rule Formes are
either one piece forgings for extended production runs, or bent Rule set in plywood backing
sheets which can be rapidly manufactured. The resulting shape pinched out of the parent material
is consistently sized and repeatable. Hole punches are also fitted in the appropriate places to
simultaneously create any required holes in the gasket. Low or high volume parts can be
produced with semi-automated repetition machinery and kiss-cutting to produce reels of parts.
This can often be a convenient method of handling small punched parts. Standard cutters are
available for products such as flange and joint gaskets to BS EN 12560, and special cutters for
bespoke parts can be manufactured in 48 hours.

Water Jetting
involves a very high pressure jet of water approximately 0.1mm diameter being blown through a
sheet of parent material to cut it, driven around the sheet via a CNC controller. This technique
allows soft or hard, solid or cellular materials to be cut rapidly into an infinite variety of shapes
very quickly, and without the deformation often found in the punching methods. However
materials that absorb water clearly are not suitable for this process.

Laser Cutting
A process very similar to water jetting, but replacing the water jet with a laser. The benefits are
very similar, although the wetting problem may be replaced by an equivalent flammability
problem.

Hand Cutting
The most traditional yet still effective method. TACL’s Rubber is still called on daily to hand-
mark out shapes in sheet material, then use knives and saddle punches to create special or large
gaskets for customers.
Strip Cutting
A rotary knife press cuts long sheets of material into strip form using a series of circular
rotation knives, with the distance between each blade being set to determine the width of the
strip produced. Still a very efficient way of converting sheet material into a finished product.

Finishing
Company dedicated skilled finishers to ensure that your product is not only manufactured, but
also trimmed, finished and packed to the excellence that we maintain throughout our
manufacturing cells, meaning that there is a level of craftsmanship akin to the quality level you
would expect.
3.3Moulding process
SUPPLIER(COMPOUND)

RECEIPT INSPECTION

RMS

raw rubber carbon

KNEEDER

MACHINE(mixing)
chemical
oil
EXTRUDER

MOUDLING

TEAR OFF

FINAL INSPECTION

PACKING

DISPATCH
METALLIC-RING GASKET:-Metallic gaskets are usually constructed from one grade of
metal to a predetermined size and shape. The most widely used type of metallic gasket in the
process industry is the ring-type joint, which can be used at elevated pressures and temperatures.
Ring-joint gaskets, are manufactured to ASME B16.20 to suit flanges designed to ASME B16.5
and ASME B16.47. The API 6A standard covers both flanges and matching gaskets, which can
be divided into three distinct groups:

 Style R, either ring or octagonal.

 Style RX, a pressure-energized adaptation of the standard style R ring-joint gasket.
 Style BX, pressure-energized ring joints designed for use on pressurized systems up to
20,000 psi (138 MPa).

Flange faces using BX-style gaskets come in contact with each other when the gasket is correctly
fitted and bolted up. The BX gasket incorporates a pressure-balance hole to ensure equalization
of pressure, which may be trapped in the grooves.

METALLIC GASKETS are fabricated from one or a combination of metals to the desired shape
and size. Often used metallic gaskets are ring-type-joint gaskets (RTJ). They are always applied
to special, accompanying flanges which ensure good, reliable sealing with the correct choice of
profiles and material.

Ring Type Joint gaskets are designed to seal by "initial line contact" or wedging action between
the mating flange and the gasket. By applying pressure on the seal interface through bolt force,
the "softer" metal of the gasket flows into the microfine structure of the harder flange material,
and creating a very tight and efficient seal.

ASME B16.20 covers materials, dimensions, dimensional tolerances, and markings for metallic
and semi-metallic gaskets.

Typical RTJ gaskets

RING GASKET:- RTJ gasket and Dimension Chart for Oval and Octagonal Ring
Gasket. Ring gaskets are also known as RTJ gasket or O-ring Gaskets. These gaskets are used
for high-pressure services. They are solid rings of metal (cut from plate, pipe or a forgedring) in
different cross sections such as oval, round,octagonal.
Special RTJ gasket comes with a hole in the center for pressure equalization in subsea pipeline
application. You can see the different type of RTJ gasket in the image below.

Ring Joint Gaskets are used with Ring Type Joint (RTJ) flanges. A high surface stress is
developed between an RTJ gasket and the flange groove when RTJ gasket is bolted to a flange.
This leads to plastic deformation of this gasket. Thus, the hardness of the gasket is kept less than
the hardness of the flange groove. The only thing you have to take care is that hardness of the
gasket shall always be less than flange material by at least 50 BHN.
Type of Ring Type Joints Gasket

There are three types of RTJ gasket. They are

 R Type
 RX Type
 BX Type

R Type

This is the basic type of RTJ gasket and widely used in petrochemical industries. They are
classified as two types base on the cross-section. They are

 Oval
 Octagonal

The original design of the R type gasket is Oval. The octagonal RTJ is a modification to the oval
design and provides better sealing. R type rings are used for the flange rating from Class 150 to
2500. The surface finish of the gasket shall not be rougher than 63µ inches.

The octagonal type is highly used when to compare with oval type because of high sealing
efficiency.
RX Type

RX type gaskets are fit into the same groove sizes of R type gaskets for interchangeability. The RX type
gasket is wider than the R type gasket. Hence the flange face-to-face separation will be higher when
compared with the R type gasket. RX type gaskets are normally specified up to Class 5000 flanges. The
surface finish of the gasket shall not be rougher than 63µ inches. The asymmetric cross-section makes the
gasket self-energising.

This type of gasket is widely used for the application where more effective sealing required and also resist
vibrations, shock loadings, etc.,

BX Type

BX type gaskets are only suitable for API 6 BX type flanges. These gaskets are used for the Class rating
of 2000 to 20000 psi. The BX type gasket has a pressure passage hole for pressure equalization on each
sealing face sides. The surface finish of the gasket shall not be rougher than 32µ inches.
Type BX gaskets are not interchangeable with R or RX gaskets. The groove on a flange which
accommodates a BX gasket is dimensionally different to that for R and RX gaskets

The pitch diameter of the ring is slightly greater than the pitch diameter of the flange groove.
This preloads the gasket and creates a pressure energized seal. It is particularly important to
check the flange face-to-face separation which must be uniform around the entire circumference
of the flange.

Identification of RTJ Gasket

The outer surface of each RTJ gasket shall carry the manufacturer’s name or identification
trademark. The gasket number prefixed by the letters R, RX, or BX followed by the gasket
material identification. Materials shall be identified as shown in Table.

Example for RTJ Gasket Code

3.5 Metallic gasket process

SUPPLIER

RECEIPT INSPECTION

RMS

BLANKING

PUNCHING

FORMING

SAC

FINAL INSPECTION

PACKING

DISPATCH
Type: Whether R, RX or BX. If R, state whether octagonal or oval. The type of ring to
be used will be specified in the piping specification.

Ring Number: For example, R11 will fit a 1/2 inch NB with the Class rating of 300-600
RTJ flang

Material: A variety of materials is available. Based on the sealing fluid property the RTJ
gasket material will be selected. Refer below table for the material grade. For example
identification code D is for Soft Iron.

Standard: Either ANSI B16.20 or API 6A. These two standards are equivalent and
interchangeable.

RTJ Gasket Materials and Hardness

List of material that can be used for metallic gaskets and the maximum
acceptable hardness for these materials is given in ASME B16.20. Refer below
table for more information.

GASKET MATERIALS BRINELL HARDNESS ROCKWELL IDENTIFICATION

NUMBER (max) HARDNESS NUMBER

-B Scale (max)

Soft iron 90 56 D
 Low carbon steel 120 68 S

4-6% Chrome 1/2% molybdenum 130 72 F5

Type 410 Stainless Steel 170 86 S410

Type 304 Stainless Steel 160 83 S304

Type 316 Stainless Steel 160 83 S316

Type 347 Stainless Steel 160 83 S347

Type 410 Stainless Steel 170 86 S410

Composite Gasket or Semi-Metallic:-

Composite gaskets are a combination of metal and non-metal material. Different

types of combination of materials are possible based on service requirement.

Spiral wound, Metal Jacketed, and Kamprofile gasket are well known in composite
gasket category. They are used in a wide range of pressure and temperature services.
Composite gaskets are cost effective with compare to metal gaskets but Careful
handling is required. Composite gaskets are used on raised face, male-female, and
tongue-and-groove flanges.
3.4Semi-Metallic Gasket Process

SUPPLIER

RECEIPT INSPECTION

RMS

PLACING THE BOTH MATERIAL

AS PER REQUIREMENT IN THE
DIE

BLANKING/PUNCHI
NG

BORE CLOSING

FINAL INSPECTION

PACKING

DISPATCH
Spiral Wound Gasket

The most widely used composite type gasket is a Spiral Wound Gasket. It is suitable
for wide range of pressure and temperature class. Normally Graphite or PTFE used as
filler material & stainless steel or other exotic material is used as the winding
material.

There are three components in spiral wound gasket. Inner & Outer ring, filler
material, and winding material. However, sometimes an inner ring is not used. You
can see in the image spiral wound gasket with and without inner ring. The inner ring
is used to provide additional support to the winding material. The winding is an
alternative layer of filler material and winding material. The filler material is a soft
material such as graphite and PTFE and winding material is a thin sheet of metal.

Spiral wound gaskets are semi-metallic gaskets that comprise of a mix of metallic and filler
materials. These gaskets have a metal wound outwards in a circular spiral, with the filler
material wound similarly, but starting from the opposite side, thus resulting in alternating layers
of metal and filler material. The metal used in these gaskets is usually carbon rich or stainless
steel, and the filler material generally used is flexible graphite. The metal provides structural
support to the equipment, while the filler acts as a sealing element. These semi-metallic gaskets
allow lower clamping forces than solid gaskets, and are used in a majority of applications. Even
 though they are a little costlier than other gaskets, people prefer these semi-metallic gaskets
over the others. Talbros automotive component ltd is one of the most reliable spiral wound
gasket manufacturers in India, whose products are ideal for applications that require gaskets
with highest quality flexibility so that they can be effectively used in conditions with fluctuating
temperatures and pressures.

 How are spiral wound gaskets manufactured?

As mentioned above, spiral wound gaskets are made by winding alternating strips of
metal and filler material over an inner ring made of special steel. Although the basic
materials are carbon rich, stainless steel, and flexible graphite; these materials can be
changed depending upon various factors. The main factors that help in deciding upon
the materials to be used include chemical compatibility, fluid concentration, corrosive
nature, operating temperature, and material cost. Because the spiral wound gaskets
depend upon the mechanical characteristics of a formed metal spiral strip, they are
particularly suitable for low or fluctuating bolt loads. However, you must keep in mind
that the spiral must not be over compressed, if you require effective and long-lasting
operation. The completed gasket with alternating spirals of metal and filler material is
fitted into a steel ring of specified thickness. When the gasket is fitted into a flange and
bolt load is applied, the outer steel ring governs the flange closure. To further enhance
the gasket’s pressure rating, a steel ring can be added to the inside that also protects
the windings from contamination or any similar damage.

 Where are spiral wound gaskets used?

The spiral wound gaskets or semi-metallic gaskets are designed for the widest range of
operating conditions of temperature and pressure. They are used in raised face flanges,
male and female flanges, and tongue and groove flanges. They are also reliably used in
high-temperature and high-pressure applications.

The spiral wound gaskets manufactured by Talbros Automotive Component Ltd. are
made up of stainless steel 304, 316, or 321. The general filler materials used are
graphite or asbestos. The outer ring of such gaskets is made up usually of carbon steel.
The most highly recommended spiral wound gasket is the one with flange face finish of
63-250 AARH. So, for the best-in-class semi-metallic gaskets, you can get in touch with
 Talbros Automotive Component Ltd., one of the leading and respected spiral wound
gasket manufacturers in India. Other than these semi-metallic gaskets, you can also
purchase from a range of metallic and non-metallic gaskets too.

Spiral wound procedure

SLITTING SLITTING FILLER GROOVE

FORMING
(ss 304) MATERIAL
V&W TYPE

GRINDING S.S WINDING (SS AND

TRIMMING(EXTRA
SLIT &FILLER FILLER)
S.S SLIT &SLOT
MATERIAL TO
WELD) JOINT SS FACE
MAINTAIN
SPOT WELDING
THICK

INSPECTION AND
PACKING
TIEING

2.3 Products made by the company

Material Combinations Used in Spiral Wound Gaskets
Properties
As mentioned above, spiral wound gaskets are made up of layers of metal and filler
materials. This construction is highly beneficial as a sealant when intense and fast
loading effects are applied to a flange. The materials used in such gaskets are carefully
chosen, and those that are known for their ability to compress and recover under load
are only selected. When fastening bolts are tightened around a toughened flange, the
layered metal and filler strips bind together to create a tenacious seal. Other exclusive
properties of spiral wound gaskets include long lasting performance, elastic recovery,
improved pressure rating, and better performance in low/fluctuating bolt loads. With all
these amazing properties, spiral wound gaskets are used to eliminate leaks, drops, and
pressures, while enhancing safety and normal operations. They also prevent escape of
air, gas, and water in commercial and industrial situations.

Applications
Although these spiral wound gaskets are used in applications where high temperature and high
pressure are seen, but they can also be used in low temperature applications like in cryogenic
facilities, chemical plants, and research laboratories, where low temperature storage solutions
and subsidiary equipment coolant mechanisms are seen. Other applications where spiral wound
gaskets are used are in extremely toxic applications like chemical processing plants and
petrochemical refineries. You can see spiral wound gaskets placed in pumps, pipes, valves,
heat exchangers, and other equipment that are used in a wide variety of industries like
chemical, petroleum, power generation, metallurgy, and shipbuilding. This is because the
materials used in building these gaskets is carefully chosen to withstand high temperatures,
high pressures, and corrosion effectively.

Camprofile gaskets:-
Camprofile gaskets consist of a metal core, generally stainless steel, with concentric grooves on
either side. A sealing layer is usually applied on both sides and depending on the service duty
the material for this layer can be graphite, PTFE (Teflon®), asbestos free gasket sheeting
material or metal (e.g. aluminium or silver). The sealing layers protect the flange surfaces from
damage in addition to providing an effective seal.

Characteristics
• The wide seating stress range (minimum to maximum seating stress) of the camprofile gasket
makes it: - Highly suitable for varying temperatures and pressures. - Less sensitive to assembly
faults (inaccurate bolt tensioning). - Suitable for light and heavy designed flanges. • Dependent
upon the layer material camprofile gaskets can resist temperatures up to approx. 1000°C.

• Resistant to media pressures up to 250 bar.

• When assembled the remaining thickness of the sealing material is extremely low (0.1 - 0.2
mm), thus reducing leaks, fail rates and environment pollution.

• The gasket will not damage the flange surface and can be easily removed.

• Camprofile cores are re-usable after cleaning, inspection (including profile tracing) and
relayering with new sealing material. This is of particular interest in the case of costly heat
exchanger gaskets (when using Monel® for instance, and other exotic materials).

• Reduces maintenance costs and leakage - thanks to the camprofile gasket’s reliability and
sealing performance.
Seating stress range
A camprofile gasket offers a reliable sealing performance when seated within the following
seating stress ranges: The above values are based on parallel root form gaskets. The values

have slight variations for convex root form gaskets.

Flange surface finish

The recommended flange surface finish for camprofiles with sealing layers is from 3.2 to 6.3 μm
Ra (125-250 RMS), also referred to as a smooth finish, however stock finish is acceptable as
well.

Core thickness
Core thickness depends on the assembly circumstances. The most common camprofile core thickness
nowadays is 3 mm. When a camprofile is replacing an existing gasket, the use of a 4 mm. thick core
should not be problematic. Only in very exceptional situations using a thicker gasket might cause
unnecessary stress on existing pipe runs, this especially in rigid systems.

Advantages of parallel root cores

• Uniform spread of stress at the cams

• Uniform spread of stress across the flange surfaces

Advantages of convex root cores

• Highly suitable for underbolted flanges

• Effective seal at low seating stress

• The gasket design ensures a high seating stress area (centre) and a lower seating stress area (gasket’s
outside)

Gasket profiles

All profiles feature a standard profile with a 1 mm cam pitch and a maximum groove depth of 0.5 mm.
Alternative profiles are available on request e.g. 1.5 mm cam pitch and a maximum groove depth of 0.75
mm (DIN profile).

Profile selection
Camprofile gaskets with centering rings ensure optimum gasket positioning between the bolts.
Thermal-shock conditions (sudden changes in temperatures) may damage camprofiles with
integral centering rings (thermal tension may cause cracks in the core). This is prevented by
using camprofile gaskets with floating guide rings.The centering rings on styles SM21 and SM41
allow for expansion and contraction without reactionary forces being applied to the core.

The SM21 and SM41 styles offer the following advantages

• The guide ring is stable and free from expansion stresses.

• No distortion of the centering ring by the threads of the bolts, as sometimes occurs in vertical
assemblies, causing the camprofile to be positioned eccentrically. This also increases the
possibility of re-use, reducing costs in the long run!

• The floating guide ring allows for expansion without applying mechanical stress to the
camprofile core.

Core material selection

The core material is generally fabricated in identical material to the piping system to prevent
corrosion problems.Stainless steel 316 camprofiles cores are generally used with carbon steel
pipe systems to prevent gasket corrosion. The recommended camprofile metal cores are shown
in the table.

*Standard material for camprofile gasket

Layer material selection

The following table may be used to determine the appropriate sealing layer material. Seaco recommends
the use of graphite layers for most applications. Only in cases where graphite may cause media pollution,
or is not chemically resistant, an alternative layer material should be chosen.

Graphite

This is a universal, high quality, non-asbestos sealing material featuring:

• Very good chemical resistance

• Resistance to high (fluctuating) temperatures and pressures

• Non ageing properties

• Excellent gas tightness qualities The standard graphite quality used has an ash content of < 2% and
chloride content < 50 ppm.

PTFE (Teflon®)

Is a high quality synthetic material featuring:

• Excellent chemical resistance

• Temperature resistant up to 250°C

• Good ageing resistance

• Excellent gas tightness

Non-asbestos materials consist of synthetic fibre compounds with nitrile rubber binders and mineral
fillers.

Silver is a precious metal combining excellent gas tightness and chemical resistance properties. Generally
used in applications requiring gas tightness at elevated temperatures.

Metal jacketed gasket

With a high resistance to blow out, metal jacketed gaskets are ideal for high assembly
stress situations.
These gaskets are made using a thin metallic outer shell that contains a resilient filler material.
The metal casing protects the filler and is resistant to pressure, temperature and corrosion.
SMITH Gaskets hand-makes their metal jacketed gaskets and provides them in a variety of
shapes and sizes,
with a selection of metals and fillers available.
Best suited to sealing flat surfaces of gas pipes, heat exchangers, cast iron flanges and
autoclaves, metal jacketed gaskets can be useful when dealing with irregular or faulty flange
rims.
 DOUBLE JACKETED GASKETS

Integral Construction Welded Construction

SINGLE JACKETED GASKETS

Single jacketed gaskets have one surface and both OD and ID covered by the metal
jacket. Suitable for narrow flange widths in low pressure valve/pump applications.

DOUBLE JACKETED GASKETS

Double jacketed gaskets are completed enclosed by a two piece metal covering
OD, ID and both sealing surfaces. Widely used in heat exchange applications
and suitable for corrosion and high temperature service.

Selection of Gasket

Proper selection of gasket depends upon following factors.

1. Compatibility of the gasket material with the fluid.

 2. Ability to withstand the pressure-temperature of the system.

3. The service life of the gasket

It is important to understand the requirements of particular applications before

making gasket selection. Gaskets must maintain a seal for an acceptable period
against all the operational forces involved. There are eight important properties
which any gasket must possess to achieve this –

1. Impermeability – The gasket should not be porous to the fluid being sealed.
2. Compressibility – The gasket should compress into the imperfections on the flange
sealing faces to create the initial seal.
3. Stress relaxation (creep resistance) – The gasket should not show significant flow
(creep) when subjected to load and temperature. Such flow will allow the bolts to
relax, reduce gasket surface stress and cause leakage.
4. Resilience – Although normally stable, flanges do in fact move slightly relative to one
another under the influence of cycling temperature and pressure. The gasket should be
capable of compensating for such movements.
5. Chemical resistance – The gasket should withstand chemical attack from the process
medium being handled. Likewise, the gasket material itself must not contaminate the
process medium.
6. Temperature resistance – The gasket should be able to withstand the effects of the
maximum and minimum temperatures within the process and the external atmospheric
temperatures.
7. Anti-stick – The gasket has to be easily removable after use.
8. Anti-corrosion – The gasket must not cause corrosion of the flange faces.

Improvements
Many gaskets contain minor improvements to increase or infer acceptable operating conditions:

 A common improvement is an inner compression ring. A compression ring allows for higher
flange compression while preventing gasket failure. The effects of a compression ring are
minimal and generally are just used when the standard design experiences a high rate of failure.
 A common improvement is an outer guiding ring. A guiding ring allows for easier installation and
serves as a minor compression inhibitor. In some alkylation uses these can be modified on
Double Jacketed gaskets to show when the first seal has failed through an inner lining system
coupled with alkylation paint.

Reasons for failure

Uneven distributed pressing force
Uneven pressure can be caused by a variety of factors. First is the human factor: asymmetric
application of the bolt preload, this can cause uneven pressure. Theoretically when the flanges are
pressed, the sealing surfaces are absolutely parallel, in practice however, the centerline of a pipeline
cannot be absolutely concentric, and tightening the bolts on the flange moment makes the flange a
discontinuity. With asymmetric connections, the seal surfaces will be more or less deformed and the
pressure reduced, the running load, prone to leakage. Third, the density of bolt arrangement has an
obvious impact on the pressure distribution, the closer the bolts, the more uniform the pressure.
Stress relaxation and torque loss
Tighten the bolts on the flange. Due to vibration, temperature changes, and other factors such as
spiral wound gasket stress relaxation, the bolt tension will gradually decrease, resulting in loss of
torque, causing a leak. In general longer bolts and smaller diameters of bolt are better at preventing
the loss of torque. A long thin bolt is an effective way to prevent torque loss. Heating for a certain
period of time to stretch the bolt, and then maintaining a given torque, is very effective in preventing
the loss of torque. When the gasket is thinner and smaller there will be a greater loss of torque. In
addition, prevent strong vibration of the machine and the pipe itself, and isolate them from adjacent
equipment vibration. Impacts on the sealing surface are not meaningless. Not impacting the
tightened bolts can prevent the loss of torque.
Surface not smooth
It is important to make the sealing finish properly otherwise it will cause leakage. A surface that is
too smooth can allow your gasket material to blow out under pressure. A surface that is not
machined flat can provide leak paths. A good rule of thumb is a machined surface to 32RMS. This
insures the surface is flat, but with enough surface finish to bite into the gasket under compression.

4.2 System for handling

Receive material
Material and non- conformance

in it
Inspect Ok
Clear MRIR in ERP

Not ok
Reject material in ERP
 Decide
disposal action

Reject

Handover rejected
material to store
for sending back
to supplier

Raise CAR
Not ok
Reject Clear
Ok MRIR

Not ok Verify action ok

as per CAR