Common Spiral Wound Gasket Failures and How to Prevent Them ?

Spiral wound gaskets are among the most widely used sealing solutions in industries like oil and gas, petrochemicals, power plants, and heavy manufacturing. Known for their ability to withstand extreme temperatures and pressures, these gaskets are critical for maintaining leak-free joints in pipelines, valves, and flanges.

However, despite their durability, spiral wound gaskets (SWGs) can fail if improperly selected, installed, or maintained. Such failures can lead to costly downtime, product loss, environmental hazards, and even safety risks for workers. Understanding the common causes of failure—and knowing how to prevent them—is crucial for business owners, engineers, and maintenance teams.

In this comprehensive guide, we’ll explore the most common spiral wound gasket failures, their underlying reasons, and practical prevention strategies.

What Are Spiral Wound Gaskets? A Quick Recap

Before diving into the failures, let’s briefly understand the construction of a spiral wound gasket:

• Metallic Winding Strip: Provides mechanical strength and resilience.
  
• Filler Material (Graphite/PTFE/Mica): Offers sealing properties under pressure and temperature.
  
• Inner and Outer Rings (optional): Maintain alignment, improve load distribution, and prevent over-compression.
  

This combination makes spiral wound gaskets versatile, but it also means improper specification or installation can lead to performance issues.

Why Gasket Reliability Matters for Businesses ?

For industries where downtime costs thousands of dollars per hour, gasket reliability is non-negotiable. Failures not only disrupt operations but can also:

• This leads to fugitive emissions, violating environmental regulations.
• Create safety hazards for workers.
• Increase maintenance and replacement costs.
• Damage brand reputation and client trust.

Being proactive about gasket selection, installation, and maintenance ensures long-term operational efficiency and compliance.

Common Spiral Wound Gasket Failures

1. Blowouts Due to Overpressure

Description:

A blowout occurs when the gasket material is forcibly expelled from the flange joint due to excessive internal pressure. This is one of the most dangerous types of failures.

Root Causes:

• The gasket is not rated for the operating pressure.
• Improper seating stress or torque during installation.
• Flange misalignment leading to uneven pressure distribution.

Impact on Businesses:

Unplanned shutdowns, product loss, and potential injury or fire hazards.

Prevention Tips:

• Verify the gasket’s pressure rating against actual operating conditions.
• Use a torque wrench or hydraulic tensioning to apply a uniform bolt load.
• Ensure flanges are properly aligned and surfaces are clean.

2. Leakage Due to Improper Installation

Description:

Leaks occur when the gasket fails to create a proper seal between the mating surfaces.

Root Causes:

• Uneven bolt tightening.
• Damaged or dirty flange surfaces.
• Incorrect gasket size or thickness.

Impact on Businesses:

Continuous leaks may go unnoticed, causing long-term product loss, corrosion, and safety issues.

Prevention Tips:

• Train maintenance personnel on proper installation practices.
• Use a calibrated torque sequence (typically star-pattern tightening).
• Clean and inspect flange surfaces before placing the gasket.

3. Creep Relaxation and Loss of Bolt Load

Description:

Over time, gasket materials may relax or compress further under load, reducing the bolt tension and the sealing force.

Root Causes:

• High operating temperatures cause filler material to degrade.
• Insufficient bolt preload during installation.
• Using low-quality or non-specified gaskets.

Impact on Businesses:

Gradual loss of sealing integrity, especially under cyclic temperature or pressure conditions.

Prevention Tips:

• Choose filler materials suited to operating temperatures (e.g., graphite for high heat).
• Retorque bolts after the system reaches operating temperature.
• Use gaskets from certified suppliers.

4. Chemical Attack on Filler Material

Description:

Exposure to incompatible chemicals can break down the filler material, causing leaks or structural failure.

Root Causes:

• Mismatch between filler material and process media.
• Lack of corrosion-resistant metallic winding selection.

Impact on Businesses:

Accelerated wear, increased replacement frequency, and environmental hazards from chemical leaks.

Prevention Tips:

• Consult chemical compatibility charts before selecting gasket materials.
• Use PTFE fillers for aggressive chemicals or graphite for non-oxidizing conditions.
• Consider corrosion-resistant metal windings like stainless steel or Inconel.

5. Thermal Cycling Damage

Description:

Repeated heating and cooling cycles cause expansion and contraction of gasket materials, leading to stress and micro-leaks.

Root Causes:

• Flanges or bolts are not designed to accommodate thermal expansion.
• Poor material selection for high thermal cycling conditions.

Impact on Businesses:

Frequent maintenance shutdowns, increased risk of leakage during startup/shutdown cycles.

Prevention Tips:

• Select gaskets designed to handle temperature fluctuations.
• Use inner and outer rings to enhance stability.
• Periodically retighten bolts after several cycles.

6. Over-Compression or Crushing

Description:

Applying excessive bolt load can crush the gasket, deforming its sealing elements.

Root Causes:

• Lack of torque control during installation.
• Using a gasket without load-distribution rings.

Impact on Businesses:

Reduced gasket life, leakage, and higher maintenance costs.

Prevention Tips:

• Always use recommended bolt torque values.
• Install outer rings to prevent over-compression.
• Conduct training for installation teams.

7. Flange Misalignment and Surface Damage

Description:

Improperly aligned or damaged flanges can lead to uneven gasket compression and premature failure.

Root Causes:

• Mechanical stress on piping systems.
• Corroded or warped flange faces.

Impact on Businesses:

Chronic leaks and repetitive gasket replacements.

Prevention Tips:

• Inspect flange flatness and surface finish before installation.
• Use flange alignment tools during assembly.
• Repair or resurface damaged flanges where necessary.

8. Incorrect Gasket Storage and Handling

Description:

Gaskets stored improperly can become damaged or contaminated, affecting their performance.

Root Causes:

• Exposure to moisture, sunlight, or dust.
• Physical bending or deformation during storage.

Impact on Businesses:

Reduced shelf life and compromised sealing performance.

Prevention Tips:

• Store gaskets in a dry, temperature-controlled environment.
• Keep them flat and in the original packaging until use.
• Train staff on proper handling procedures.

How to Prevent Spiral Wound Gasket Failures: A Comprehensive Checklist

1. Material Selection

• Match filler material with chemical and temperature conditions.
• Use stainless steel, Inconel, or Monel windings for corrosive environments.

2. Correct Installation Practices

• Follow the manufacturer’s torque specifications.
• Use cross-pattern tightening for uniform load.
• Include inner and outer rings where applicable.

3. Regular Maintenance and Inspection

• Schedule periodic checks for bolt tension and leaks.
• Replace gaskets during planned shutdowns, not after failures.
• Keep a record of gasket performance and replacement intervals.

4. Training and Certification

• Train maintenance personnel and supervisors on gasket handling and installation.
• Partner with suppliers who offer on-site training or consultation.

5. Partnering With Trusted Suppliers

• Source from reputable manufacturers who provide test certificates, quality checks, and technical support.
• Ask for ASME B16.20 or API 601 compliant gaskets where applicable.

Industry Applications: Where Gasket Reliability Is Critical

• Oil & Gas Pipelines: High-pressure and high-temperature systems.
• Petrochemical Plants: Corrosive chemicals and frequent thermal cycling.
• Power Generation Units: Steam lines and boiler systems.
• Pharmaceutical & Food Processing: Cleanroom conditions with strict sealing requirements.

These sectors cannot afford unscheduled downtime; thus, preventive measures are essential.

Cost Implications of Gasket Failures

A seemingly small gasket failure can have massive cost implications:

• Unplanned Shutdowns: Loss of production hours.
• Environmental Fines: Leaks of hazardous chemicals.
• Reputation Damage: Loss of customer trust due to safety incidents.
• Increased Maintenance Costs: Emergency callouts and part replacements.

Investing in quality gaskets and preventive measures saves money in the long run.

Spiral Wound Gasket Standards and Compliance

When purchasing gaskets, ensure they comply with international standards:

• ASME B16.20
• API 601
• EN 1514-2
• BS 3381

Compliance ensures reliability, consistency, and safety across applications.

Emerging Trends in Spiral Wound Gaskets

• Advanced Materials: Use of high-performance alloys and filler materials.
• Digital Monitoring: IoT-enabled flange monitoring for bolt tension and leak detection.
• Eco-Friendly Solutions: Non-asbestos fillers and recyclable materials.
• Supplier Partnerships: End-to-end technical support from manufacturers.
  

These trends are making gaskets safer, more durable, and easier to maintain.

Final Thoughts

Spiral wound gaskets are essential for maintaining leak-free, reliable operations across industries. While these gaskets are robust, their performance depends heavily on correct selection, installation, and maintenance practices. By understanding the common failure modes and implementing the prevention strategies outlined in this guide, businesses can significantly reduce downtime, improve safety, and save costs.

Remember: investing time in training, material selection, and periodic inspections is far cheaper—and safer—than dealing with a gasket failure after the fact.