The work presented here is a collaborative approach to achieving a reliable gas tight seal in fiberglass reinforced plastic (FRP) flanged joints using expanded polytetrafluoroethylene (ePTFE) gaskets. There are many advantages to incorporating FRP flanged piping systems in today’s chemical process industry plant build. As regulations on reliability and fugitive emissions become stricter, it is more important than ever to eliminate possible damage and leak paths at the flanged connections in these systems. This paper details a case study on a collaboration between a chemical plant operator (end user), an ePTFE gasket manufacturer, and a FRP piping original equipment manufacturer. Over a twenty-four month period a FRP flanged system was designed and validated using a custom FRP stub and ring, also known as a lap joint, flange with an ePTFE gasket. The result was the development of a FRP bolted flange system that successfully achieved a reliable gas tight seal for aggressive chemicals. Beginning with a theoretical model and ending with experimental lab analyses, the conclusive results are included herein.

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