Flange gasket is the core component of pipeline and equipment flange sealing system. OnceFailure of flange gasketIt is prone to medium leakage, material leakage, pressure relief and other faults, which can seriously affect the safe and stable operation of the entire equipment. In actual working conditions,Reason for damage to flange gasketVery complex, commonly including improper installation and assembly, uneven bolt pre tightening force, flange sealing surface deviation, high and low temperature alternation, system pressure fluctuations, water hammer impact, medium corrosion aging, incorrect gasket selection, product quality defects, and many other situations. different materialsMetal wrapped gasket, rubber gasket, PTFE gasket, graphite gasketThe failure manifestations of damage, cracking, swelling, and creep relaxation are also different. To completely solve the problem of flange leakage, it is necessary to accurately determine the type of gasket failure and avoid common issues such as installation, working conditions, and material compatibility from the root.
1、 Installation and assembly issues (most common)
- Improper pre tightening force of bolts
- 拧得过松:密封面压不紧,介质渗漏、垫片被内压鼓破;
- 拧得过紧:垫片被过度压缩压溃、撕裂,非金属垫压扁失去回弹;
- 螺栓对角分次紧固不到位、单边紧:法兰偏斜,垫片局部受压过载断裂。
- 法兰错口、翘曲、平行度超标
法兰变形、错位,垫片受力不均,局部挤压破损,缝隙窜介质冲蚀垫片。
- 垫片选型错误
高压用低压薄垫、高温用不耐温橡胶垫、腐蚀介质用普通石棉 / 橡胶垫,短时间溶胀、脆裂。
二、温度工况因素
- 冷热交变疲劳
启停设备温度忽冷忽热,垫片反复膨胀收缩、回弹老化,出现裂纹、碎裂;非金属垫高温碳化、低温变硬脆裂。
- 超温超设计温度
超过垫片耐温上限:橡胶老化碳化、石墨垫氧化粉化、四氟高温蠕变塌陷失效。
三、压力波动与介质冲刷
- 系统压力骤变、水锤冲击
启停泵、阀门瞬间冲击压力击穿垫片,内侧被介质冲击掏空破损。
- 介质腐蚀 / 溶胀
酸碱、油品、有机溶剂浸泡:橡胶溶胀变软挤出;金属缠绕垫钢带被介质点蚀穿孔;四氟被特殊溶剂溶胀开裂。
四、密封面缺陷
法兰密封面划痕、凹坑、锈蚀、磕碰缺口,垫片无法填平缺陷,高压介质切入垫片慢慢割裂破损。
五、垫片本身质量问题
- 原材料劣质:橡胶含胶量不足、石墨杂质多、金属带厚薄不均;
- 加工缺陷:缠绕垫松散、点焊脱落、垫片厚薄不均,受压局部断裂。
六、外在环境老化
露天管线日晒雨淋、臭氧老化,橡胶类垫片变硬开裂;水汽渗入缠绕垫夹层锈蚀钢带,垫片解体。
七、垫片安装辅材误用
缠绕垫加装定位圈漏装、加装多余填料,或垫片内外径尺寸不符:内径偏小被介质冲刷、外径偏大被法兰夹碎挤出。
八、蠕变松弛(长期服役失效)
长期高温 + 压力,垫片发生蠕变,厚度持续变薄、密封压紧力下降,逐渐渗漏、破损(金属缠绕、四氟垫高发)。
快速区分失效类型小技巧
- 垫片单边撕裂→法兰不平 / 上紧偏载
- 垫片整体压扁碎裂→螺栓过紧 / 超温
- 内侧孔洞冲蚀→介质冲刷、水锤
- 发泡溶胀→介质腐蚀选型错误