The quantities of leak rate through sealing systems are being regulated because of the global concern on the hazardous pollutants being released into the atmosphere and their consequences on the environment and health. The maximum tolerated leak is becoming a design criterion, and the leak rate for an application under specific conditions is required to be estimated with reasonable accuracy. In this respect, experimental and theoretical studies are being conducted to characterize the gas flow through gaskets and packing rings. The amount of the total leak that is present in a gasketed joint or a valve stem packing is the sum of the permeation leak through the sealing material and the interfacial leak at the mating surfaces between the sealing element and mechanical clamp assembly. The existing models used to predict leakage do not separate these two types of leaks.

This paper deals with a study based on experimental testing that quantifies the amount of these two types of leaks in bolted gasketed joints and packed stuffing boxes. It shows the contribution of interfacial leak for low and high contact surface stresses and the influence of the surface finish as a result of a 32 and 250 micro-inch RAAH phonographic finish in the case of a bolted flange joint. The results indicate that most of the leak is interfacial reaching 99% at the low stress while the interfacial leak is in the same order of magnitude of the permeation leak at high stress reaching 10−6 and 10−8 mg/s in both packing and gaskets, respectively.

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