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Recently, an OEM (original equipment manufacturer) that makes large filter units for food-grade services was reporting leaks on the cover gasket that they were using. The gasket in service was a 22” OD (outer diameter), 1/8” thick EPDM (ethylene propylene diene monomer) rubber full-face gasket with eight ¾” studs (as shown below). 

This design had two problems; not enough stud load to compress the EPDM rubber to adequate seating stress and the end surface of the filter unit was not flat. Below is a photo:

Reducing the gasket area and increase the thickness of the gasket to 1/4″ was ERIKS proposed solution to address these problems.  The new gasket looks like this:

Recently, an OEM (original equipment manufacturer) that makes large filter units for food-grade services was reporting leaks on the cover gasket that they were using. The gasket in service was a 22” OD (outer diameter), 1/8” thick EPDM (ethylene propylene diene monomer) rubber full-face gasket with eight ¾” studs (as shown below). 

This new customized gasket has 48% less material to squeeze, so we were able to increase the gasket stress by more than 50%, while also reducing the stud stress. Since the middle of the end plate looks crowned, we suggested ¼” material in order to make contact around the perimeter. In addition to changes in the design, we also wrote up a full installation procedure that included 1/4th torque increments plus a ringer pass.

This OEM customer was very happy and wrote us to say that:

“The new gaskets have been installed, and they have no experienced zero leaks.”

Since this is a versatile solution this “beaded” gasket can be applied to any lightly loaded application.

Did you know that ERIKS has also developed a sealing protocol where the expectation is a leak-free operation? The ERRIC (Evaluation, Radial Shear, Relaxation, Installation, Certification) system protocols have been used in tens of thousands of heat exchangers around the world. Click here to learn more about the ERRIC sealing system.

Click here to learn more  about the ERRIC sealing system >

Have you ever had a hose “bubble” right behind, or very near, the fitting?

Your hose assembly is extremely vulnerable nearest the fitting. Therefore, it is very important to select the proper fitting to match the hose and application.

Let’s look at a rubber 300 psi multipurpose air and water hose and review the two most common reasons this may happen.

Fitting too aggressive

Many distributors have a crimper for their hydraulic hoses and will crimp a hydraulic fitting with its barbed end onto a rubber multipurpose hose, sometimes, without issue. However, you need to select the proper fitting to match both the construction and pressure rating to the hose. (FYI – a hydraulic style fitting is not recommended for use on a standard air and multipurpose hose).

If the barbs on the fitting are too aggressive, they will bite through the tube causing a leak path. Material being conveyed through the tube will find the path of least resistance, and when the pressure builds up, air or water will escape through this leak path to form a bubble behind the fitting.

Or, the material will wick its way through hose by following the reinforcement, and where ever the cover is compromised, and that’s where the bubble will form.

You may think you need a more aggressive fitting for a hose with a high working pressure. However, the best course of action is to check with a reputable fitting manufacturer for a suitable fitting recommendation and coupling procedure.

Flex/Stress Point

Another cause of a hose failure right behind the fitting is because this is where the greatest amount of flexing and stress is put on the hose. If the hose bends at the point where the stem of the fitting ends, there is an opportunity for the stem to cut into the tube of the hose, and causes a similar scenario, where material migrates through the leak path and a bubble is formed.

Using a bend restrictor, spring, or strain reliever can reduce the amount of wear at this vulnerable point.

What to do

If you question whether the fitting or crimp is incorrect, or if the hose has a manufacturing defect, it is essential you return the end of the hose with the fitting intact to the manufacturer or fabricator of the hose. They need to see how the fitting was installed, then examine the tube of the hose where the fitting was in contact, to identify the problem and recommend a solution.

Are you having trouble tracking and inspecting your hose assemblies? ERIKS offers a complete survey, tracking, and hose reclamation program. Click here to complete a quick form to download our Industrial Hose Maintenance Management brochure to learn more.

Click here to complete a quick form to download our Industrial Hose Maintenance Management brochure to learn more >

Your industrial hose supplier should be aware that tube erosion (typically called the popcorning) in steam hose is most pronounced in hoses on the market which have tube of inferior rubber. The popcorn effect is what destroys a steam hose and the steam network. It is also what can injure workers when a hose fails. Popcorning destroys steam hose from within and the effect occurs when:

Microscopic water particles collect in the wall of a hose. When new steam enters the hose it heats up those particles, which expand explosively to 1600x their size.

When that happens, popcorn-like blisters explode on the hose’s inner surface. The resulting particles of rubber can contaminate the steam network or the product.

Over time, moisture forces its way out towards the skin of the hose, weakening the steel braiding and making it unsafe for use.

The popcorn effect is most pronounced when hoses are built with an inferior tube compound.

To prevent blistering or popcorning on the inner surface of steam hose, Goodall® formulated a premium, proprietary Chlorobutyl compound that’s 15x less permeable than EPDM. Even after thousands of hours of stop-start use, the Super Inferno, Inferno, and Dante hose shows no signs of popcorning. The lower the permeability, the longer the hose life, the greater the safety.

The Goodall range of Chlorobutyl hoses are:

  • Made of an abrasion and ozone-resistant EPDM in a distinctive red and black spiral striping for high visibility in all situations
  • The hose inside is pinpricked to significantly reduce the likelihood of cover blisters
  • Inside, multiple high tensile wire braids add plenty of integrity to handle a maximum pressure of 250 PSI at temperatures ranging from -40°F to 450°F

Goodall also formulated a high grade EPDM tube compound that provides excellence resistance to the effects of popcorning, resulting in durable, long-lasting steam hose assemblies.

Click here to complete a form download a technical datasheet for more information on the Goodall® steam hose products.

Download a technical datasheet for more information on the Goodall® steam hose products >

Your conveyor system is one of the most important elements of your operation so it’s critical that you work with a partner that understands just that. The simple truth is that you need a supplier that understands your operation, needs and knows conveyor systems like the back of their hand so that you don’t have to.

Here’s a quick checklist when selecting a conveyor system provider:

  1. Do they provide surveys and inspections of your location? You want someone that knows conveyor systems. Period. You want to know that you’re using the best product available, that you’re only experiencing the number of change-outs necessary and that you’re reducing your total cost of ownership and that you have more uptime than downtime.
  2. Do they have service crews and downtime support? You need a supplier that can be there when you need them. Whether it’s for installation, troubleshooting or preventative maintenance services having access to specialists, especially during an emergency is key.
  3. Do they have an in-depth knowledge of everything that’s available? Some suppliers only know heavyweight belt that’s used in heavy traditional industry. Some only know lightweight belting products that are used in industries like Food and Beverage and Agriculture. Your supplier should be well-versed in both. Why? Because product innovation only comes from knowing trends, understanding what’s available and knowing the right solution to apply to each individual circumstance. A supplier should also be very familiar with every component and accessory used in all different types of systems. From pulleys and idlers to chute liners and safety cages – your supplier should evaluate everything and do what it takes to keep you running straight.
  4. Are they experienced with servicing customers like me? Does this supplier have experience servicing your industry or even your competitors? Are they aware of common issues that I might face on a regular basis? Do they understand my needs both individually and as a whole? If they are not taking the time to learn by conducting an in-depth evaluation then you might need to shop around.
  5. Will they prove the value that they’re providing? Your supplier should always be thinking of ways to help you which ultimately will save you money.
    • Did they install a product substitution that resulted in less change-outs than before?
    • Are they providing innovative solutions that’s reducing or avoiding downtime?
    • Are they helping me reduce the labor needed? Are they available around-the-clock whenever I need them?

If you’re questioning any of these responses there are conveyor belt suppliers out there that will partner with you 365 days a year 7 days a week to ensure the smoothest operation possible. But of course the question is always, what have you done for me lately? Having a supplier that keeps documentation of what they do for you is helpful, especially when you can show a cost savings as a result of the partnership.

  1. Do they provide on-site training? You may need to understand the product and their applications so that you can handle emergencies if they arise. Sure, it’s always nice to have someone to call and rely on in the case of an emergency but wouldn’t it be great if you could be the hero of the day? Some suppliers will train your entire staff on various topics from safety to troubleshooting problems. In-person training that meets your needs is also a token of a solid supplier.

In summary, everyone is different and has unique needs and you want a conveyor belt supplier that understands what yours are, and that can be there immediately to help you when you’re in a bind. Besides, the work that you do is too important not to reduce your downtime as much as possible.

Click here to download an example of how ERIKS processes prevented a customer from replacing a belt and avoided downtime.

Download an example of how ERIKS processes prevented a customer from replacing a belt and avoided downtime.

For a great marksman, hitting the center of a target is not a problem. You set up a target, and he can hit it. In fact, he can hit it all day long; because this is what he does. However, all his skill and confidence won’t help him a bit if he’s presented with two targets and not told which one he is to hit. Which one should he focus on and which one should he ignore?

Such is the problem with many flange torquing standards, especially in regard to heat exchangers. In the majority of cases, existing assembly procedures for heat exchangers call out a specific stud stress that should be targeted. That stress level may be 40%, 50%, or 60% of yield, and that same value is applied – almost without exception – to all heat exchangers in the plant, regardless of pressure ratings, the number and size of the studs, the gasket size, or a host of other factors. Success – in so far as tightening the exchanger is concerned – is defined by how much a stud is stretched. It’s an easy target to hit. But is it the right target?

Many studies have been completed which show that long-term sealing of bolted connections is all about gasket stress. To be more precise, it is about attaining the needed stress, and maintaining that stress in the face of the relaxation that can be anticipated in the joint.

The ruling parameter in determining the assembly torque required for a given joint must always be gasket stress, not stud stress.

Studs don’t seal flanges, gaskets do. The “target” must be the gasket stress needed for optimal performance. Because of this, it is necessary for your gasket supplier to:

1. Evaluate the gasket area

2. Then evaluate the pressure interactions and the desired gasket stress

3. Calculate the stud stress that must be developed to achieve that end

To put it simply, any assembly specification that is based on achieving a specific stud stress is aiming at the wrong target. In fact, any such specification can only develop the optimal gasket stress by accident, or by coincidence. The only way to make sure that the correct gasket stress is achieved is by targeting gasket stress.

Click here to download a technical note on the importance of using gasket stress instead of stud stress when torquing your heat exchanger flanges.

Click here to download a technical note on proper torquing techniques.