KLINGER GPI NEWS

Cost Savings Potential of Sentry gaskets

Mon, 14 Jul 2025 14:27:46 GMT

Cost Savings Potential of Sentry Gaskets

By KLINGER GPI | 7/14/2025

By accelerating plant restarts Sentry gaskets are a true game-changer in maintaining operational efficiency. Discover how KLINGER's Reverse Integrity Gaskets streamline pressure testing processes, drastically cutting down testing time.

In the realm of industrial maintenance, time is of the essence. Accelerating process workflows without compromising on safety or efficiency is a perennial challenge. Here’s where KLINGER’s Reverse Integrity Gaskets show their mettle. These specialized gaskets have proven to significantly cut down the pressure testing time, a critical procedure in the maintenance of pressure safety valves and gas metering orifice plates.

A leap in pressure testing efficiency

In a recent scenario, a facility aimed to fit three fuel gas metering orifice plates and recertify or replace nine pressure safety valves during a more-than-one-week outage. The traditional approach to pressure testing was turning out to be a bottleneck:

» Typical pressure test for each pressure safety valve: 1 hour

» High-pressure (HP) gas plate: 6 hours

» Medium-pressure (MP) gas plate: 8 hours

» Low-pressure (LP) gas plate: 24 hours

The conventional methods demanded roughly four days of continuous work to complete the testing. However, with KLINGER’s Reverse Integrity Gaskets, the scenario took a positive turn.

Potential in cost savings

Utilizing Reverse Integrity Gaskets for pressure testing showcased a stark contrast in time-efficiency:

» Maximum of 1 hour per joint for pressure testing

» 15 joints tested, saving over three days of testing time

» Over € 1.4 million saved in plant downtime.

The gaskets are engineered for straightforward application. The pressure test volume is meticulously minimized to only test the actual joint, with pressurization achieved through a hand pump, eliminating the need for hoses.

Introducing the range of Sentry reverse integrity gaskets

Oliver Bache, Sales Director at KLINGER UK

However, KLINGER’s Sentry gaskets are changing the game. These gaskets are engineered to facilitate leakage testing on individual flanged joints, determining their tightness before introducing internal pressure. KLINGER GPI offers a diverse range of Sentry reverse integrity gaskets, each designed to cater to specific industry needs and flange types, ensuring comprehensive coverage across various operational requirements. For example, in high-pressure and potentially hazardous pipelines, the usage of metallic gaskets is a norm given the enormous safety risks involved in the event of a failure.

» The Sentry RTJ is specifically crafted for ring joint flanges, providing a robust seal and integrity check for high-pressure environments.

» For applications requiring cathodic protection, the Sentry IK emerges as a tailored solution, safeguarding against corrosion while ensuring joint integrity.

» The Sentry DS is designed with raised face flanges in mind, offering a reliable sealing solution that accommodates conventional flange types.

» Meanwhile, the Sentry SR caters to clamped connections, a common requirement in various piping systems, ensuring a secure and leak-proof seal.

Role of gaskets in fuel gas metering orifice plates

Gaskets play a pivotal role in ensuring the integrity and accuracy of fuel gas metering orifice plates, which are utilized to measure the flow rate of fuel gases in pipelines. The gasket between the flanges of the orifice plates is crucial to prevent any leakage, which could potentially lead to inaccurate readings and hazardous situations. Thus, having a reliable gasket like the Sentry gasket is imperative to ensure the safety and precision of the metering system.

Balancing efficiency and fitting considerations

"Though highly efficient, it's noteworthy that these gaskets are slightly thicker than standard gaskets. This aspect should be factored in during planning to ensure adequate room for fitting and a tight seal."

Oliver Bache, Sales Director at KLINGER UK

KLINGER has indeed made significant strides in addressing the challenges inherent in industrial maintenance, particularly in the realm of pressure testing which is crucial for ensuring the safety and efficiency of operations involving pressure safety valves and gas metering orifice plates. By introducing the Reverse Integrity Gaskets, KLINGER has showcased a remarkable solution that not only accelerates the pressure testing processes but also substantially cuts down the testing time, thus expediting plant restarts and enhancing operational efficiency.

A New Level of Sustainability with KLINGER Gaja

Wed, 18 Dec 2024 21:01:15 GMT

A New Level of Sustainability with KLINGER Gaja

By KLINGER GPI | 12/18/2024

The use of sustainable raw materials is at the heart of the new KLINGER Gaja gasket. With its outstanding eco-balance, this new product helps companies meet their climate targets.

Gaia, the oldest goddess of Olympus, was worshiped in ancient Greece as the creator of the universe and our planet. As Mother Earth, care for nature an sustainability would have been close to her heart. Ans so it is with us. Which is why our product developers have looked to classical mythology in choosing a name for their new KLINGER Gaja - the first gasket made of raw materials chosen for their low environmental impact.

The sustainable gasket

As well as being Head of Product Development at KLINGER Dichtungstechnik, Stephan Piringer is the company’s HSE Manager and, as such, is concerned about sustainability.

With KLINGER Gaja, his team came up with the answer: a universally usable gasket that has all the technical properties of a standard gasket as well as having added value for the environment.

Materials from nature

This value comes from the raw materials, which are largely not of fossil origin and therefore have an unprecedented ecological balance. The key constituents of the KLINGER Gaja gaskets are natural rubber, cellulose fibers, bio-circular silica, and untreated natural mineral fillers. These materials are largely renewable and can be sustainably sourced. The additional substances used in producing some of the gaskets are also chosen for their low environmental impact: no plasticizers, mineral oils or anti-aging agents are used.

Improved eco-balance - not just for customers

The sustainability of KLINGER Gaja is reflected in its looks: Unlike other gaskets, it has not been colored, further boosting its environmental credentials. It is also for this reason that KLINGER Dichtungstechnik is using bio-ethanol as a solvent in the production of KLINGER Gaja. “This makes us pioneers in sustainability and enables us to already supply our customers with products that reduce their ecological footprint,” says Stephan. In preparation for the product’s presentation at this year’s Achema trade fair, KLINGER has already produced its first series of sealing sheets. Around one ton of the sheet material is already in stock.

Forward-looking and certified

Stephan is confident that a sustainable sealing product like KLINGER Gaja will catch the attention of forward-looking and ESG-oriented industries. Designed for non-critical media such as water, oils, fuels, hydrocarbons, inert gases and alcohol at moderate temperatures, the gasket is certified to DIN DVGW and TA-Luft and is DNV GL approved.

Fact box

Did you know ...

» ... that KLINGERSIL gaskets are colored so that they can be identified even without a legible type designation? The different color codes, made up of the gaskets’ colored front, back and cross-section, stand for their product designations. That’s why the gaskets are always shown from both sides in product catalogs.

» ... that 15 percent of the gasket materials used at KLINGER Dichtungstechnik are recycled? This is done by collecting the offcuts of punched-out material sheets, grinding them and blending the grounds into new gasket materials.

» … that bio-circular silica is produced from rice husks? This waste from food production is available in enormous quantities, making it viable for large-scale upcycling.

40 Years and Counting: Celebrating KLINGER GPI's Financial Manager

Thu, 27 Jun 2024 18:30:08 GMT

40 Years and Counting: Celebrating KLINGER GPI's Financial Manager

By KLINGER GPI | 6/27/2024

From part-time filing to Financial Manager, KLINGER GPI celebrates Debbie Lindbloom for 40 years (and counting) of exceptional service and dedication.

Debbie Lindbloom's decades of knowledge and experience are invaluable to KLINGER GPI's past, present and future success. Her lifetime career of hard work and team-oriented mindset are foundations of KLINGER GPI's culture.

How it started

In the summer of 1983 in Borger, Texas, Debbie began at KLINGER GPI, formerly named Gasket & Packings, Inc., filing a few hours a week. She began to help out with customer service in a part-time role for a couple of years. This turned into a full-time position with added responsibilities of overseeing the bookkeeping. As the company was rapidly growing, Debbie and her close friend and coworker, Karen Felker, started to wear many hats as there were only a small handful of employees at the time. "At one time, Karen and I did all of the purchasing, inventory and customer service. We were a two woman band. When a customer came in, we would go to the warehouse and pull what they needed and then typed out the invoice. No computers at the time, just memory," Debbie remembers. "I even cut and stamped out a few gaskets when needed."

How it's going

Throughout the years, KLINGER GPI expanded in West Texas with added locations in Amarillo, Lubbock and Odessa, Texas. During this time, Debbie was put over the customer service and accounting departments. She was hiring and training new staff in all locations as well as managing the day-to-day of both departments. Along with this, Debbie was also doing the financials for the company. This eventually led to her current role as KLINGER GPI's Financial Manager. With the KLINGER Group acquisition of Gasket & Packings, Inc. in January 2020, and the 2023 merger with KLINGER's gasket manufacturer in Houston, Texas, Debbie's role as Financial Manager has grown ever more important.

We asked Debbie a couple of questions to get an understanding of where her loyalty and long-tenure comes from.

Q: What has kept you with KLINGER GPI for over 40 years?

Q: What makes the workplace so special for you?

Because of Debbie's extensive knowledge in many departments, she remains the top administrative expert at KLINGER GPI. Her commitment to the company's goals and team-first mindset is still a priority in her work today. Although it is doubtful that Debbie will work for another 40 years, KLINGER GPI is grateful for her valuable work-ethic, expertise and leadership.

Connecting Flanges: 10 Common Mistakes and How to Avoid Them

Thu, 30 May 2024 21:05:35 GMT

Connecting Flanges: 10 Common Mistakes and How to Avoid Them

By KLINGER GPI | 5/30/2024

Learn the correct methods for making flange connections and avoid common mistakes with bolts and gaskets.

In this how-to article, you will get to know the correct techniques for assembling flanges and learn about common mistakes made in selecting and using gasket materials, bolts and other components.

#1 Gasket material

The gasket material plays a major role in ensuring reliable, leak-tight flange connections. A common mistake is to use unsuitable material.

WRONG : Using an unsuitable gasket material, e.g. a fiber-reinforced material for applications with liquid oxygen (fire hazard!). Reusing an already used gasket. Using a gasket that is too large or fitting the gasket off-center, so that it protrudes into the pipe.

CORRECT : Select a suitable gasket material for the application and the conveyed medium. Always fit a new gasket.

Before you start, select the right gasket material for the task by calling your local KLINGER GPI representative.
Discard all used gaskets. Fit a new gasket even when only servicing a valve. A used gasket will no longer give an even seal, and turning the gasket over can also cause problems.
If the gasket is too large, parts of it can be eroded by the medium.

#2 Selecting bolts

Choosing the right bolts is vital to ensure the stability and tightness of flange connections. Unsuitable bolts can cause the connection to weaken.

WRONG : Using bolts other than those specified in the applicable standard. Using a different bolt material: bolts that just happen to be lying around do not necessarily match the flange material (e.g. stainless steel bolts on a steel flange). Not using washers. Mixing different bolts or using ones that are rusty or too small.

CORRECT : Use bolts, nuts and washers of the correct type, size and material as specified in the relevant standard.

The number of bolts to use with each flange is standardized and depends on the flange size and pressure.
Example: A flange of DN100 PN40 requires 8 bolts with an M20 thread. The standard applicable here is EN 1091-1 or DIN 2572.

#3 Opening the flange connection

Correct opening of the flange connection is crucial for safety during maintenance work. An incorrect procedure can lead to dangerous situations.

WRONG : Undoing the bolts closest to your own body first and removing them immediately. Undoing the bolts one after the other going round in a circle.

CORRECT : When undoing bolts, always start on the side furthest away from your body. Undo the bolts a bit at a time, always releasing diagonally opposing bolt pairs. With the nuts still in position, check whether the flange can be moved.

Safety first: If the pipe still contains a medium or is still pressurized, the medium will escape. When you undo the bolts furthest away from your body first, the medium will escape away from your body.
If the bolts are removed entirely, any tension in the pipework can cause the pipe to move towards you and cause injuries.

#4 Removing the gasket

When peeling off the gasket, take care to avoid damaging the flange surface, as this can cause leakage.

WRONG : Removing the gasket from the flange using a spatula. Undoing all bolts and opening the flange connection immediately.

CORRECT : Leave the nuts and bolts on the flange connection. Move the flanges slightly to ensure that the gasket does not adhere. Clean the flange with a brass wire brush. The grooves in the flange’s mating surface are visible on the gasket.

Spatulas are usually as hard as or even harder than the flange material. They can cause scratches in the flange or rust to form, and this may result in leakage.

#5 Lubricating the bolts

Lubricating the bolts is important to ensure that the forces are evenly distributed and to facilitate assembly.

WRONG : Not lubricating the bolts.

CORRECT : Apply the specified lubricant to the bolts around their entire circumference. Also, apply lubricant between the nut and the washer.

The lubricant to use is also specified in the shop papers.

#6 Assembling the flange

Correct assembly of flanges, especially in vertical applications, is vital to ensure that the connection is stable and tight.

WRONG : Tightening the bolts on a flange in a vertical application by going round in a circle. Securing the gasket between the flange surfaces using adhesive or double-sided adhesive tape. This can lead to problems during operation.

CORRECT : For vertical pipework, first fit threaded bolts or centering bolts to the underside to ensure that the gasket does not slip through.

For full-faced flanges: The gasket covers the entire flange surface and already contains holes for the bolts.
For raised-face flanges: The sealing surface is slightly higher than the rest of the flange surface. This is the most common flange type.

#7 Positioning the gasket

Positioning the gasket correctly is essential to ensure that the flange connection works as intended. Incorrect positioning can cause leakage.

WRONG : Positioning the gasket at an angle so it protrudes beyond the flange or into the pipe.

CORRECT : Always center the gasket on the flange surface. When the flange is opened, the imprints of the flange grooves on the gasket are even all the way around.

With set bolts, the gasket cannot slip. When using shoulder bolts, however, the use of centering bolts is recommended.
The gasket can be glued on with a small drop of adhesive so that it does not slide out of position in a vertical installation. A better option is to fit bolts to the underside of the flange to prevent the gaskets from slipping out.

#8 Nuts and bolts

Using the correct combination of nuts and bolts is important to ensure the integrity of the connection and to avoid problems when re-tightening.

WRONG : Separating the nuts and bolts when opening a flange connection, so that the nuts and bolts are later refitted in different combinations.

CORRECT : Keep each nut-and-bolt pair together after disassembly. When reassembling the flange, refit each nut to the bolt to which it was originally fitted.

A precise fit between the nut and bolt is vital so the flange connection has the required tension and strength. The thread and tolerance of each nut and bolt is slightly different, so it is important to match nuts and bolts correctly.

#9 Torque spanner

The correct use of tools plays an important role in precisely controlling the necessary tightening torque. This ensures an even load distribution.

WRONG : Using an open-end or ring spanner and tightening the bolts using random force. This can lead to the mating pressure to be spread unevenly over the flange and gasket, which can damage the connection.

CORRECT : Use a calibrated torque spanner to ensure that all of the bolts are tightened to the same, correct torque. Tighten the bolts in several stages, working in a crosswise pattern. Finally, tighten each bolt again to the same torque, working in a circle around the flange. This ensures that all bolts are equally tight and none have been missed.

Using a torque spanner ensures that the bolt forces are evenly spread across the whole flange. This is particularly important, as uneven forces can cause damage to the gasket or even the whole flange connection.

Example: If you apply 200 kN, this corresponds to a mass of 20 metric tons. This means that the flanges exert a pressure of 20 tons on the gasket. That is why it is important that these forces are spread evenly.

#10 Tightening the bolts

Tightening nuts and bolts in the correct order and to the correct torque is critical in the assembly of flange connections. It ensures an even load distribution and the structural integrity of the joint. Errors in this step can lead to considerable problems and safety risks.

WRONG : Tightening nuts and bolts to the full torque going around the flange in a circle. This causes an excessive load on the first bolt and may result in others remaining insufficiently tightened. The gap between the flange halves may then be uneven and the first bolt could even break under the load.

CORRECT : First tighten the nuts and bolts finger-tight. Then tighten them in a crosswise pattern in several stages, each time gradually increasing the torque. This ensures that the load on all bolts remains even and prevents the flange from tilting.

Crosswise tightening of the bolts ensures that their forces are evenly distributed on the flange and gasket. This is vital to prevent damage to the gasket, flange and bolts.
Tightening a bolt to its limit can easily cause it to rupture. Tightening in a circle without first finger-tightening can result in the entire tightening force being required for the first half of the flange to straighten the flange again.

A comparison

In this example, the bolts were tightened once in a circle moving around the flange (image A, WRONG) and once in a crosswise pattern (image B, CORRECT). The forces acting on each bolt and the gasket thickness were measured in each case. A torque spanner was used in both cases.

Please note: This blog post does not guarantee a leak-free installation. This how-to article explains the ten most common mistakes and misconceptions when assembling flange connections with gaskets. If you have any questions, please get in touch with your contact person.