T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -

Technicalspecification

and usageguide

1224 North Utica . Tulsa . Oklahoma 74110T: 918 587-6649 . F: 918 587-6961 . E: info@topog-e.comW: www.topog-e.com

GASKETS

The requirements of a superior boiler gasket. 3Expected service life in steam boiler application 4Maximizing service life of Topog-E® gaskets in steam boilers 6

Stress relaxation & manual over-tightening during installation 10The environment of steam pressure vessels 12

Material specification sheet – Molded gaskets and sheet material 15Material specification sheet – Special food grade 17Material specification for alternative elastomeric materials 18Refrigerant compatibility recommendations 19Applications and product range 21

BOILERS

General boiler care 23Cleaning a boiler’s gauge glass. 25How to determine if a sight glass is full or empty. 26Caring for an out of service boiler. 27Understanding steam 28Steam safety pop valves 32Appendices 34

Installation of Topog-E® gaskets 38THE TOPOG-E GASKET COMPANY HAS BEEN MANUFACTURING AND

The Topog-E Gasket CompanyTechnical Specification and Usage Guide

© Copyright TOPOG-E GASKET COMPANY 2004This information is Copyrighted by Topog-E Gasket Company. This information is to be used byTopog-E® authorized distributors and customers only. Any reproduction or transmission of thisinformation in any form or by any media for any purpose other than its intended use is aviolation of Federal Copyright unless explicit permission is granted by Topog-E Gasket Company.

The requirements of a superior boilergasket

THE STEAM BOILER ENVIRONMENT MAKES EXTREME DEMANDS ONGASKETS; A TOPOG-E® RUBBER GASKET IS SPECIFICALLYFORMULATED TO MEET THEM AND DELIVER INDUSTRY STANDARDPERFORMANCE.

Topog-E® rubber gaskets have been refined through a series ofover 600 research formulation tests, to ensure that they are ableto meet the exacting performance standards of steam boilers. Asuperior boiler gasket must:

■ Conform to the topography of the mating surfaces■ Withstand the boiler’s full, continuous, and sometimes

fluctuating operating pressure.■ Withstand continuous exposure to appropriate boiler

treatment chemicals.■ Withstand continuous exposure to ion and oxygen attack in

the hot air outside the boiler shell.■ Stop all leakage.■ Replace easily without any chiselling or buffing.

A properly installed Topog-E ® gasket meets, and exceeds, all theserequirements. The Topog-E Gasket Company continues to researchall the factors that affect gaskets – including cure characteristics,tensile and tear strength, accelerated ageing, modulus,compression set and stress relaxation – to ensure that wecontinue to remain at the forefront of technological advances.

R E Q U I R E M E N T S / 32 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E

Expected service life in steam boilerapplication

When used on steam pressure vessels, Topog-E® gaskets aretypically used at operating pressures of up to 180 PSI (12 bar) and380º F (193º C) for an average service life of twelve months. Thislevel does not represent an absolute upper service limit for Topog-E®gaskets; rather it represents the approximate highest andcontinuous pressure level at which one can expect to obtain anaverage service life of twelve months from properly installed Topog-E® gaskets.

Because there are many factors – some of which are applicationspecific- that can affect the service life of a Topog-E® gasket, it isimpossible to develop a precise, accurate table of expected servicelife versus operating pressure / temperature. However, it isimportant to remember that the action which causes Topog-E®gaskets to degrade over time is primarily a chemical reaction withthe oxygen in the atmosphere. Increasing the temperatureaccelerates this reaction, and thus the higher the operatingtemperature of the boiler, the shorter the service life obtained.

The following table was prepared, based on actual customer useand extensive testing, to be used as a general guide forestimating approximate service life for properly installed Topog-E®gaskets in steam pressure vessels:

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Continuous Operating Approximate MaximumSteam Pressure in PSI (bar) Service Life in Months(1)

Below 25 (2) 18-2425-100 (2-7) 12-18100-180 (7-12) 12-15180-200 (12-14) 10-12200-225 (14-16) 8-10225-250 (16-17) 6-8

The Topog-E Gasket Company invests heavily in research anddevelopment efforts to insure that Topog-E® gaskets live up totheir worldwide reputation for quality, durability, and ease of use.Topog-E® gaskets are tested in-house at steam pressures andtemperatures far exceeding the 180 PSI (12 bar) and 380º F(193º C) levels below which most Topog-E® gaskets are used insteam applications. Carefully installed and monitored Topog-E®gaskets are routinely subjected for extended periods of time tosteam pressures and temperatures of up to 360 PSI (25 bar) and438º F (226º C). However, we do not actively recommend servicein boilers at these elevated levels because we have no control overhow our gaskets are installed and because there are alwaysunique application specific factors that can affect both theinstallation and service life obtained with Topog-E® gaskets.

Remember that the best way to maximize the service life of aTopog-E® gasket is to follow closely the installation instructionsprovided with the gaskets.

Finally, regardless of operating pressure, we recommend thatTopog-E® gaskets be changed out at least every twelve months, inconjunction with a regularly scheduled equipment shutdown andinspection.

(1) These figures arebased on generalcustomer experience,and do not representany guarantee ofservice life for Topog-E® gaskets. Actualservice life obtainedmay vary.

Maximizing service life of Topog-E®gaskets in steam boilers

WHEN INSTALLING

The Topog-E ® gasket is designed to offer specific and aggressiveresistance to the hostile atmosphere of live steam and todemonstrate minimum deflection under load. We recommend alimit of 180 PSI steam (12 bar) and 380º F. (193º C.) in steamboiler applications. This is not stated as a maximum upper limit,but since we have no control over the mounting of the gaskets inthe field, it is a statement of reasonable expectation of servicecapability. The following precautions, if observed, can helpmaximize the service life of Topog-E ® gaskets.

■ The curvature of the cover plate should match the curvature ofthe boiler shell.

■ Observe good housekeeping; let clean metal surfaces bear onthe gasket at all times. Be sure that no encrusted matter orresidual pieces of another gasket material are on the boilershell or plate.

■ We do not recommend the use of sealants, adhesives, or anti-seize compounds with Topog-E ® gaskets. Our own tests andfield experience suggest that these materials, especially whenused in large amounts can lead to premature failure of thegasket for at least three reasons:

– Uncured portions of this material can act as a lubricantrather than an adhesive (esp. RTV silicone), thereby making itmore difficult to get the gasket properly aligned and seated. It

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also increases the chance that the gasket may slide orextrude out after installation due to a lack of friction.

– Cured portions, if spread on too thickly and/or unevenly, canmake it more difficult for the gasket and internal pressure toeffect a proper seal in the normal manner.

– Adding another material with a different chemicalcompatibility profile than the gasket can lead to problemsdepending on the exposure media.

■ Machine the crabs to a true 90º from the vertical axis so thatan absolutely balanced stress acts on the gasket.

■ Press the gasket into firm contact with the cover plate, and thebolt gasket, if used, into firm contact with the bolt head.

■ Center the gasketed cover plate exactly on the opening, thenapply the crab. Tighten only enough to hold the assembly in place.

■ Start making steam. As the gasket heats, stress relaxationoccurs and leakage will occur. At this stage tighten onlysufficiently to stop serious leakage and ignore hissing. Followthis procedure in gentle stages until the internal pressureitself causes the seal.

■ Keep the crab snug. In the event of shutdown, inverse pressurewill displace a loose cover plate, violating the seal. Once anescape path has been established for the steam or water, it canbe difficult to reestablish a seal with complete integrity. Thiscan also have the effect of exposing larger localized areas ofthe gasket to the atmosphere (in similar fashion as wouldreinstalling a used gasket).

HELPFUL HINT

It is essential to

always replace

with a fresh

gasket if a seal is

ever broken.

Remember, the

cost of an

unplanned boiler

shutdown is far

greater than the

cost to install a

fresh set of

Topog-E® gaskets!

HELPFUL HINT

Misaligned plates

often occur in

bottom inspection

openings where it

is hard to see if

they are aligned.

Using an

inspection mirror

helps determine

proper alignment,

and ensures equal

pressure

distribution over

the gasket.

■ Minimize as much as possible the amount of outside air thatreaches the annulus of rubber that is exposed and subject tooxidation. Properly centering the cover plate will helpsignificantly in protecting this vulnerable area of the gasket.Sometimes the design and age of the plate and opening canhave an effect on this level of exposure. Badly worn or pittedareas on the shell or plate can allow increased exposure of thegasket to the atmosphere.

■ Never overtighten!! A properly mounted gasket is held in placeby internal pressure, and is secured from shifting by the crab.In this manner, the rubber never witnesses greater pressurethan steam pressure, and thus its elastic memory will not beexceeded.

OTHER FACTORS

■ ALWAYS FOLLOW THE ADVICE OF A QUALIFIED WATERTREATMENT SPECIALIST. The proper use of boiler water andsteam line treatment formulations is essential for efficientboiler operation. Over many years we have analyzed thechemicals that are used on a regular basis in treatmentformulations. Data compiled from solubility parameters,chemical resistance data, suppliers’ guidelines, customerfeedback, and input from treatment specialists, suggest thatthere should not be a noticeable effect on the service life of aproperly installed Topog-E® gasket from the normal use ofthese water and steam line treatments when used inaccordance with treatment specialists’ guidelines. Boileroperators should always seek and follow therecommendations of a reputable water treatment specialist,as doing so increases system efficiency, prolongs the life ofexpensive equipment, and minimizes the potential for

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chemical compatibility problems with various systemcomponents (e.g. gaskets).

■ NEVER RE-USE A GASKET!! Some Topog-E® gaskets areremoved at the end of a year’s service looking as if they arecapable of completing another year’s work. We do notrecommend re-use under ANY circumstances, as it can resultin expensive boiler failure and shut-down during thesubsequent year. There is some evidence that suggests that ifan inspection plate is opened – or in some way the seal isbroken – after several months of service, and then reinstalledand tightened with the same gasket, it is possible that aproper seal is never recaptured because of the permanent“set” or impressions made in the gasket after several months’service. This could lead to an increased rate of degradation atspecific points, resulting in an abbreviated service life.

■ HOT SPOTS: Some gaskets are located close to hot flue gasescontaining the products of combustion from the boiler. Thehigher temperature makes oxygen more active, and theproducts of combustion contain more ozone. These “hot spots”can cause these gaskets to age quicker and typically lookworse than their companion gaskets upon removal.

HELPFUL HINT

A sheet-metal

baffle plate can

sometimes

reduce the heat

and flow of gases

to the area around

the gasket.

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Stress relaxation & manual over-tightening during installation

STRESS RELAXATION IS A VISCO-ELASTIC RESPONSE OF ANELASTOMER WHEN COMPRESSED WHILE IN SERVICE. THISRELAXATION IS PROMOTED BY SUCH STRESSES AS HEAT,COMPRESSION, ELONGATION, AND SHEAR.

If this relaxation proceeds at a measured pace, very littleimpairment is caused to the physical properties profile of thegasket. When a combination of stresses, one of which is heat, isvisited on rubber, relaxation is specific with this heat. Thecompressive stress must be coordinated with heat relaxation, butif applied at a rapid rate and maintained (i.e. by prematurely over-tightening), irreversible damage is caused to the gasket, and ashortened service life can be expected. Remember, manual over-tightening (especially when applied all at once in the cold state)can sometimes subject the Topog-E® gasket to a shearing forcewhich can slice through the gasket and substantially weaken it,thereby impairing its inherent resistance to the force of internalpressure. In addition, the rate at which rubber is attacked by thehot, dry, oxygen-laden air from outside the boiler increases as theamount of stress (compression) increases. Consequently, eventhough over-tightening doesn’t always cause a gasket to fail dueto shearing force, it can cause the gasket to age quicker so that itappears in a much worse state upon removal (e.g. more brittle,cracks, etc.). Topog-E® gaskets can normally take a good deal ofabuse and still perform satisfactorily. However, when over-tightening is combined with, or is a result of, misalignment ofgasket and/or plate, the chance of premature failure cansometimes increase dramatically. This situation – wheretightening is applied unevenly – can often create abnormally high

and severely concentrated pressure points that can, incombination with moderate over-tightening and internal pressure,lead to a gasket’s rupture. In fact, when a gasket is not properlyseated or the plate is not properly aligned, it is possible that theposition of the gasket actually makes additional tighteningnecessary in order to stop the seepage caused by the inability ofinternal pressure to make a seal in the usual manner.

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The environment of steam pressurevessels

EVEN UNDER IDEAL CONDITIONS, TOPOG-E® GASKETS WILLDETERIORATE OVER TIME.

The three principal factors that cause this natural degradation inelastomeric material, oxygen, stress, and heat, are interdependentand synergistic (i.e. working in concert these factors create amore hostile environment than they do when acting independentlyof each other).

1. Atmospheric oxygen is the cardinal agent of harm to therubber gasket in service, and its effect increases significantlyin the presence of the other two elements.

2. Stress is the compressive effect - the reduction in thicknessbrought about by the steam pressure of the boiler.

3. Heat and steam pressure are gradients of each other in anexponential relationship. As a generalization, it may be statedthat the speed of a reaction doubles for each 18ºF. (10º C) risein temperature. Refer to the Topog-E® Steam TemperatureCalculator to calculate specific temperatures and pressures(we will be happy to send you one upon request).

Topog-E® proprietary gasket material has specific and aggressiveresistance to the hostile environment of live steam. If very lowoxygen content is present in the steam, trouble rarely arisesinside the boiler with a properly mounted Topog-E® gasket. The realtest is outside the boiler where a thin periphery of the gasket isexposed to the atmosphere that contains 21% oxygen. Thiscomponent is highly corrosive to rubber, an effect which increaseswith heat, pressure, and the amount of gasket surface areadirectly exposed to the outside atmosphere.

The situation is further complicated by the fact that rubber understress degrades more rapidly than rubber that is not. Unperturbed,survival of a rubber component is measured in years, while understress, it is most often measured in terms of months. This is why itis important to follow the installation instructions and theprecautions listed in the section: Maximizing Service Life in orderto insure that the optimal service life of Topog-E® gaskets isachieved.

A system like the one used in Topog-E® gaskets can sealeffectively for periods averaging one year in a steam pressurevessel, even though the outer surface of the gasket will graduallycrack and degrade under the unremitting and combined attack ofoxygen, stress, and heat. The 180 P.S.I. (12 bar) level does notrepresent an absolute upper service limit for Topog-E® gaskets;rather it represents the approximate highest and continuouspressure level at which one can expect to obtain an averageservice life of twelve months from properly installed Topog-E®gaskets. Customers have reported using Topog-E® gasketssuccessfully in steam pressure vessels operating at pressuresmoderately higher than 180 P.S.I. (e.g. 200-250 P.S.I. / 14-17 bar),and it is important to note that doing so is not imprudent orinherently unsafe, especially if the Topog-E® gaskets are carefully

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installed. However, it must be remembered that the higher thesteam pressure and corresponding temperature, the shorter theexpected service life of the gasket becomes.

The Topog-E Gasket Company invests heavily in research anddevelopment efforts to insure that Topog-E® gaskets live up totheir worldwide reputation for quality, durability, and ease of use.Topog-E® gaskets are tested in-house at steam pressures andtemperatures far exceeding the 180 PSI (12 bar) and 380º F(193º C), levels below which most Topog-E® gaskets are used insteam applications.

Material Specification Sheet – MoldedGaskets and Sheet Material (StandardMaterial)MATERIAL DESCRIPTION: SPECIAL, PROPRIETARY RUBBERCOMPOSITION, BLACK, 80-85 DUROMETER.

When used on steam pressure vessels, Topog-E® gaskets aretypically used at operating pressures of up to 180 PSI (12 bar)and saturated steam temperatures up to 380º F. (193º C.) for anaverage service life of one year. When used in other applications(e.g. condensate, water, and air vessels), Topog-E® gaskets aresometimes used at pressures above 200 PSI (14 bar) wheretemperatures are typically more moderate (e.g. below250ºF./121ºC.). When operating under less severe conditions (e.g.water applications at ambient temperatures) Topog-E® gasketscan provide very long service lives.

Topog-E® gaskets have been used successfully around the world forover forty years. In general, any type of industrial pressure vessel ortank that has inspection openings is a potential application whereTopog-E® gaskets can be used as a cost effective sealing device. Inaddition to using them in steam pressure vessels, customers also useTopog-E® molded gaskets and sheet material with great success inmany other applications, including: water softeners, hot water heaters,steam humidifiers and cookers, water purifiers and demineralizers,refrigeration units, liquid treatment vessels, carbon absorption andfiltering vessels, dryer cans in paper mills, water hydrants, varioustypes of mixing tanks, compressed air tanks, various types of dryers,air starters and receivers, hatch covers on railroad tank cars and riverbarges, water towers and columns, PVC reactor vessels, and inapplications where excellent low-temperature sealing properties arerequired.

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Topog-E® gaskets are specifically formulated to have excellentresistance to steam and hot and cold water. They also have goodresistance to alcohols, ketones, phosphate esters, silicone oilsand greases, dilute acids, bases, salts, glycols, ammonia, selectedrefrigerants, and animal and vegetable fats. Water treatmentchemicals, when used in accordance with supplier’s guidelines,should not have a significant effect on the service life of properlyinstalled Topog-E® gaskets. In general, Topog-E® gaskets are notrecommended for use in applications where they see directexposure to high concentrations of aromatic hydrocarbons,chlorinated solvents, or petroleum based oils, fuels, andlubricants.

Topog-E Gasket Company, which formulates and mixes its ownrubber, invests heavily in research and development efforts toinsure that Topog-E® gaskets live up to their worldwide reputationfor quality, durability, and ease of use. Topog-E® gaskets aretested in-house at steam pressures and temperatures farexceeding the 180 psi and 380º F, levels below which most Topog-E® gaskets are used in steam applications. Carefully installed andmonitored Topog-E® gaskets are routinely subjected for extendedperiods of time to steam pressures and temperatures of up to 360PSI (26 bar) and 438ºF (226º C).

Because there are many application specific factors that canaffect service life, it is always advisable to first test Topog-E®gaskets in a particular application to determine their ultimatesuitability. Please contact your distributor or Topog-E® GasketCompany if you have questions regarding a specific application. Ifyou have never used Topog-E® gaskets, we would be happy toprovide you with the name of a Topog-E® gasket distributor in yourarea and a sample gasket for your evaluation.

Material specification sheet– Special Food Grade (SFG)MATERIAL DESCRIPTION: SPECIAL PROPRIETARY RUBBERCOMPOSITION, BLACK, 70-75 DUROMETER

Topog-E® SFG gaskets are typically used in low pressure foodprocessing applications such as steam cookers, sterilizers, carbonabsorption vessels, and various food and beverage mixing vesselsand processing columns that have inspection openings whichmust be sealed using a food grade gasketing material certified toUS FDA regulations. Topog-E® SFG gaskets are made from acompound that complies with the FDA Code of Federal Regulationsfor rubber and rubber-like materials under Title 21, Paragraph177.2600.

Most SFG gaskets are used in applications with operating pressuresbelow 100 PSI (7 bar) and temperatures below 300ºF (149º C).

Topog-E® SFG gaskets have excellent resistance to steam and hotand cold water. They also have good compatibility with a range offood and beverage substances, including animal and vegetablefats, whisky, alcohols, and corn syrup. Because there are manyapplication specific factors that can affect service life, it is alwaysadvisable to first test Topog-E® SFG gaskets in a particularapplication to determine their ultimate suitability. Please contactyour distributor or Topog-E® gasket Company if you have questionsregarding the chemical compatibility of Topog-E® SFG gaskets with aparticular food or beverage substance.

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Refrigerant CompatibilityRecommendations

Topog-E ® gaskets (Standard Material) should provide “good toexcellent” service when used in service with the followingrefrigerants, which should have little or no effect:

Ammonia (R-717), R-22, R-407C, R-410A, R-13, R-13B1, R-14, R-31, R-32, R-114, R-115, R-142b, R-152a, R-218, R-C316, R-C318, R-502, TA, T-P35

Topog-E® gaskets (Standard Material) should provide “fair to goodservice” when used in selected applications with the followingrefrigerants, which may have a minor to moderate effect:

R-12, R-134a, TC, TMC, T-WD602

Topog-E® gaskets (Standard Material) are not recommended foruse with the following refrigerants:

Propane (R-290), Propylene (R-1270), R-11, R-21, R-112, R-113, R-114B2, BF, MF, TF, PCA

Topog-E® gaskets (Standard Material) have been used with goodsuccess for over fifteen years in refrigerant applications,especially in those where resistance to ammonia and R-22 isimportant. These applications generally also contain process oilsin various concentrations that typically do not have a significanteffect on the service life of Topog-E® gaskets. Topog-E® ANSIgaskets, a more reinforced version of our Topog-E® StandardMaterial gaskets, are sometimes used in applications with higher

Material specification for alternative elastomericmaterials

Here are some other elastomeric materials that Topog-E Gaskets can be made from:

Topog-E® Special Oil-Resistant Material (SOR): 75-80 durometer, black.Good solvent, oil, and hydraulic fluid resistance. Temp. to 250ºF. (121ºC.)

Topog-E® Fluoroelastomer Material (FKM): 70-80 durometer, black (e.g. Viton®). Heat resistance to over 400ºF (204ºC.), good resistance to wide range of oils and solvents, esp. aliphatic, aromatic, and halogenated hydrocarbons and acids.

Topog-E® Special Food Grade Material (SFG): 70-75 durometer, black. Special material that complies with applicable FDA regulations for selected food applications.

Topog-E® ANSI Flange Material (ANSI): 87-88 durometer, black. Modified Topog-E®Standard Material for use in selected standard flange gaskets or higher pressureapplications (e.g. piping, air tanks, refrigeration vessels).

Topog-E® 70 Duro Material (70D): 70-75 durometer, black. Modified Topog-E® Material for use in selected applications that require a softer gasket material (e.g. those with very low operatingpressure).

Viton® is a registered trademark of DuPont Dow Elastomers.

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Applications and Product Range

APPLICATIONS

■ Steam pressure vessels■ Hot water heaters and demineralizers■ Steam humidifiers and cookers■ Water purifiers■ Refrigeration units■ Carbon absorption and filtering vessels■ Liquid treatment vessels■ Compressed air tanks■ Dryer cans in paper mills■ Water towers and columns■ Water softners■ Deaerators■ Make-up tanks

Because there are many application specific factors that canaffect service life, it is always advisable to first test Topog-E®gaskets in a particular application to determine their ultimatesuitability. Please contact your distributor or Topog-E GasketCompany if you have questions regarding a specific application.

operating pressures (e.g. over 200 PSI (14 bar)). Both of thesegasket materials are especially well suited to the typical operatingtemperatures of these applications – which are usually less than250º F (121º C).

For Propane (R-290), R-11, and R-12 service, we recommendTopog-E® Special Oil Resistant (SOR) gaskets. For Propylene (R-1270) service, we recommend Topog-E® Fluoroelastomer (FKM)gaskets.

Because there are many application-specific factors (e.g.temperature and pressure) that can affect service life, it is alwaysadvisable to first test Topog-E® gaskets in a particular applicationto determine their ultimate suitability.

Topog-E Gasket Company has not tested the compatibility of itsgaskets with every refrigerant listed. These are recommendationsonly, and are based on published chemical resistance data, 15+years of actual customer experience, and literature provided bymaterial manufacturers and suppliers. We are unable to guaranteethe accuracy of this information and assume no liability for theuse thereof.

G E N E R A L B O L I E R C A R E / 23

General Boiler Care

BOILER CARE FACTS AND TIPS

■ If the cover plate is too small for the opening in the boiler, it iseasy to place the cover plate off-center. An off-centerinspection plate can concentrate forces on the gasket and cutit in two. The plate may also drag on the shell and fail to sealas the pressure rises.

■ After start-up, crabs should be re-tightened as pressureincreases and the gasket seats. A loose crab on the bottom, orbelow the water line, can cause a boiler to drain or shutdownas the steam pressure lowers to zero.

■ A coating of scale is a coating of insulation. It will lower theefficiency of a boiler and cause it to use more fuel. It will causefire surface temperatures to rise beyond their designatedscope, and will insulate fusible plugs, altering their meltingtemperatures.

■ A fusible plug changes its melting point with time andtemperature and should be replaced annually for that reason.

■ Low water level is one of the most dangerous of boilerconditions, and therefore, gauge glasses should be kept clearand operational at all times. Try cocks should be kept only asa means of checking gauge glass readings and as a temporarymeasure when repairing gauge glasses.

22 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E

PRODUCT RANGE

■ Thickness: All molded gaskets are a nominal 1/4 in (6mm)thick. Molded sheets are available in 1/8 in (3mm), 3/16 in(5mm), and 1/4 in (6mm) thicknesses. Typical tolerances:gaskets +/- 1/32 in (0.8mm); sheets +/- 1/16 in (1.6mm).The tolerances will have no noticeable effect on gasketperformance.

■ Elliptical gaskets – inch sizes: Over 100 sizes of imperialstandard measure manhole and handhole gaskets arecurrently available – the vast majority of these will besupplied from stock.

■ Elliptical gaskets – metric sizes: Gaskets are available fromstock for boilers built to metric sizes.

■ Obround, round, and special shaped gaskets: These areavailable from stock to fit virtually all types of boilers andother pressurized vessels and tanks.

■ Sheet material and custom gaskets: These are supplied toorder. Any size or shape of custom-designed gasket will be cutor molded on request – set-up charges may apply.

C L E A N I N G T H E G A U G E G L A S S / 2524 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E

■ A ‘slow’ pressure gauge indicates that its anti-syphon nipple isfilled with scale and rust, and its readings are inaccurate.Brass pigtail nipples are generally more trouble-free.

■ Grease or oil in a boiler is not good. It usually causes primingor foaming, and can be seen on top of the water in the gaugeglass. To remedy, skim the water in the boiler before draining,and when refilling, add a small amount of soda ash to cut thegrease.

■ Regular blow down of a boiler removes sludge collected in thebottom of a boiler, but is no substitute for proper watertreatment which stops the formulation of sludge and scale.Boiler repair and water treatment agencies in your area will beable to advise what your water may require.

■ Fuel efficiency changes gradually. A regularly scheduledmaintenance program is more economical.

■ A gasket that leaks is eroding the boiler it is supposed to help. A properly installed Topog-E® gasket will not leak.

Cleaning a boiler’s gauge glass

Follow these simple steps precisely to clean a boiler’s gauge glasswhile steam pressure is on boiler and without disassembly.

■ Fill a cup with household ammonia

■ Close top and bottom gauge valves. Open drain valve beneathcolumn.

■ Open the top gauge valve a fraction, so steam pressure blowsall the water out of the drain line and so that the glasscontains only steam.

■ With a very gentle flow of steam out of the drain line, hold thecup of ammonia to the end of the drain line so that the steambubbles up through the ammonia.

■ Close the top gauge valve. The steam will quickly condense inthe gauge glass causing a vacuum. The resulting contractionwill suck ammonia up into the gauge glass.

Repeat until the glass is completely clean.

WARNING: DO NOT USE THIS PROCEDURE IF EITHER THE TOP ORBOTTOM GAUGE VALVE WILL NOT SEAL-OFF COMPLETELY!APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (MASKS,

GLOVES, EYE PROTECTION) SHOULD ALWAYS BE WORN WHENPERFORMING THIS OR ANY OTHER WORK ON OR AROUND STEAMBOILERS.

26 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E C A R E F O R A N O U T O F S E R V I C E B O I L E R / 27

How to determine if a sight glass is full or empty.

When no water level shows on a sight glass, you can quickly tellwhether it is completely full or completely empty. Hold a pencil, orequivalent, against the far side of the sight glass tube at an angleof approximately 45º. If the image of the pencil viewed through theglass appears to run across the glass and changes no matter whatthe angle of the pencil, the glass is full.

If the image viewed through the glass runs up and down the glassat a sharper angle than the actual angle of the pencil, the tube isempty.

Practice this procedure with the normal water level by viewingthrough the sight glass above and below the water line. Thick walltubing gives a less pronounced difference, but the difference isstill obvious.

Caring For an Out of Service Boiler.

There are two primary ways to care for an out of service boiler.These are usually chosen on the basis of whether freezingtemperatures will exist while the boiler is stored, and whether theboiler may be needed for service on short notice. The boiler can bestored dry or wet. In either case, it should be cleaned beforeservice.

DRY STORAGE

The cleaned boiler should be thoroughly dried. Any moisture willcause corrosion over time. All lines to the boiler that could carrymoisture back to it must be blocked off. (Remember, even air cancarry moisture).Moisture absorbing material may be placed on trays inside theshell at the rate of 2lbs/1kg of quick lime, or 10lbs/5kg of silicagel for each 1000gal. of capacity. Periodic inspections of theeffectiveness of these materials are recommended duringextended storage.

WET STORAGE

The cleaned boiler should be closed and filled to overflowing usingchemically conditioned water (condensate is purer than feedwaterfor this purpose). Caustic soda can be used for this treatment at aconcentration of 450ppm with an oxygen scavenger such assodium sulfite at 200ppm. Water pressure greater thanatmospheric should be maintained during storage.

28 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E U N D E R S T A N D I N G S T E A M / 29

Understanding steam

A VERY BASIC, BUT SERIOUS LOOK AT STEAM

Boilers make steam by boiling water. That is about the most oversimplified statement we can make. However, some interestingthings happen when water is boiled. At atmospheric pressurewater expands 1,600 times its original volume when it turns tosteam. This explains why a tea kettle can fill your kitchen full ofsteam.

Water at atmospheric pressure boils at 212º F (100º C). Theboiling water in an open vessel measures 212º F, the steamcoming off the surface also measures 212º F. Once boiling all thetime that heat is applied to the vessel, nothing increases intemperature. The applied energy is changing the water into steam.The steam will give-up energy before turning back into liquid. Thisenergy is called Latent Heat and for most purposes is consideredthe useable energy of steam.

Below the boiling point the heat applied to the vessel goes into thewater and raises the temperature. We are able to measure thistemperature change with a thermometer and we call this heatSensible Heat.

For most purposes for which steam is used it is the Latent Heat ofthe steam that we utilize, for after the Latent Heat is given up, thesteam condenses back into a liquid. Whenever possible we returnthis condensed steam (condensate) to the boiler for reuse. Thisconserves a large portion of the Sensible Heat we had to apply inthe first place to produce the steam. Even if the condensate hasbecome contaminated by materials that make its return to theboiler unsuitable, we can still use it to heat the incoming waterthrough a heat exchanger and thus reduce fuel requirements.

So far we have only considered an open vessel for boiling water. Ifwe seal the vessel from the atmosphere and continue to applyheat the expanding steam causes the pressure inside the vesselto increase. This increase in pressure causes the temperature atwhich the water will boil to increase. This requires further SensibleHeat to get the water to its newer, higher, boiling point. At thesame time the Latent Heat required to reduce the water intosteam is reduced. The net result is that only a slight increase inTotal Heat is required for each pound of steam. But since thatsame pound (by weight) of steam will occupy 26.8 cubic feet ofspace at atmospheric pressure and only 2.14 feet at 200lbs persq inch pressure it is more handily packaged at higher pressure.While occupying only 1/8th the volume, 200 P.S.I. steam has onlyrequired 4% more heat per pound. Smaller piping will serve thesame system and will reduce piping heat loss as well.

Steam is so

familiar to all of

us that we easily

forget what a

marvelous thing it

is. Steam will

carry 20 times the

BTU’s per pound

that Freon 12 will,

nearly 15 times

the BTUs of F22

and twice that of

ammonia. Even

when we use

nuclear energy for

power, it is only to

heat the water to

make steam. For

all this we tend to

take steam for

granted without

much thought to

how it really is

produced or how it

works best for us.

30 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E U N D E R S T A N D I N G S T E A M / 31

Steam can be in one of three conditions Wet, Dry or Superheated.

WET STEAM contains small water droplets entrained with it. Thesedroplets contain no Latent Heat and therefore have nothing tocontribute to the process before being returned to condensate.Just 6% of water particles at 200 P.S.I. reduces the Total Heat in apound of steam to less than the Total Heat in a pound of steam atatmospheric pressure.

DRY STEAM requires the elimination of water particles from thesteam line. This can be achieved mechanically with baffles in thesteam flow designed so that the water particles are deposited andleft behind, or by removing the wet steam from the water surfaceand applying additional heat to drive all of the water particles intosteam. Flue gas heat is often used for this purpose.

SUPERHEATED STEAM occurs when sufficient additional heat isapplied to raise the steam temperature to any level above that ofsaturated dry steam. Some Superheat is sometimes required toensure that dry steam is achieved at the end of long pipe runs. Itwould seem that Superheat would be the course to take in all casesas a means to transfer more heat. In reality the amount of additionalheat transferred is not great. One pound of steam at 200 P.S.I.superheated by 100º F has gone from 1200 BTUs total heat to 1260BTUs total heat (an increase of 4.8%). While that small change was

taking place the saturated steam started acting like a perfect gasand expanded in volume from the original 2.14 cu feet to 2.45 cufeet a volume change of 14.5%. Therefore the heat content per cubicfoot of steam has actually reduced by superheating.

Reflecting then, we get eight times the volume of steam in thesame space by raising the pressure from atmospheric to 200 P.S.I.but we lose 14.5% volume efficiency by superheating it by another100º F. Therefore at the same 200 P.S.I. Superheat is therefore anadvantage only when the heat requirement can be met by thesmall amount of energy in the Superheat and where the highertemperature gradient from the hotter steam is required by theprocess job.

We have not addressed many of the other areas of steam use; forexample steam trapping – which is a very necessaryconsideration in most steam systems. We have, however, beenable to address steam’s basic simplicity, its great heat transfercapabilities and the versatility of its application.

When all of these issues are considered together it is obvious thatsteam will always continue to be a very important tool forindustry. It will not become obsolete because nothing comes evenclose to having these properties.

For steam engines

or turbines, it is

often part of the

power unit’s

design to use

superheated

steam. This is a

specialized

application of

steam utilizing

the entropy of

steam (which

needs to be

treated

separately).

Suffice it to say

that after

expansion

through the

engine, the steam

has nearly all the

heat units that

were put into it,

and can often be

put to additional

use in process

applications.

32 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E

Steam safety pop valves

The term “pop valve”, often applied to safety valves, is not a badterm in that it accurately reflects the action of the valve. As thepressure of the steam within a boiler approaches the set pressureof the valve, the steam pressure on one side of the actuating discapproaches the pressure of a spring applied to the outer-side ofthe disc. When equilibrium is passed the disc starts to lift from itsseat. The moment this happens steam is released all around thedisc. The additional steam creates an artificial shoulder aroundthe circumference of the disc, thus increasing its surface area.This sudden increase in area under pressure makes the pressuremuch more unbalanced in the direction of the opening which popsthe valve to the wide-open position. This pop action preventswiredraw of the seat due to slow action.

Closure of the valve only occurs when the boiler pressure hasdropped several pounds below the set point. To ensure a tightclosure after a valve has popped under pressure the boilermaximum operating pressure should be set several pounds belowthe set pressure of the safety valve. Some manufacturersrecommend setting 10% below.

Proper installation of a safety valve is a result of carefuladherence to the manufacturer’s instructions.

A safety valve body is a part of the precision of the whole device. Ifthe body becomes distorted the valve’s integrity and calibrationwill be destroyed. Care MUST be taken to apply wrenches only tothe points required for installation.

Similarly the discharge side of the valve must not be made to bearthe weight of the discharge piping. A short nipple from the valvebody should enter the mouth of an independently supported largebell reducer or drip pan elbow leading through piping to a safedischarge area, preferably outdoors.

All piping to or from a safety valve must be at least as large as thesafety valve’s connection and the restrictive action of elbows andfriction be taken into consideration.

For a safety valve to operate properly it should be capable of beingopened to an extent that it releases all of the steam a boiler is ableto produce when operating at maximum capacity.

There is some discussion in the field about whether or not it is wise to

periodically pop a steam safety valve. Since there is the possibility of the valve

becoming incapable of proper operation due to scale coating inactive parts. The

Hydronics Institute in their Operations and Maintenance Manual for Steam

Boilers recommends an operations check on safety valves at the beginning of

the heating season and every six months. Their recommended method is to raise

the pressure until the valve pops. Whether by this, or by a hand lever, the

pressure should be high enough to blow the seat and other parts clear of any

foreign matter.

S T E A M S A F E T Y – P O P V A L V E S / 33

Boiler safety

valves are little

understood, often

incorrectly

installed, and

usually neglected.

This is a general

statement, and as

with most general

statements must

not be taken as

universally true.

There is, however,

sufficient

evidence to

warrant

discussion.

34 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E A P P E N D I C E S / 35

Metric equivalents: Steam Pressure and Temperature

In 1960, 36 countries participated in a conference to standardizeweights and measures. Many have adopted the SystemeInternational (SI) metric system that resulted from thatconference. The USA too is rapidly moving toward the metricsystem.

Steam Pressure vs. Temperature

kg per sq cm lbs per Temp Temp (kPa) sq in deg F deg C

.0 0 212 100

.140 2 219 103.5

.281 4 224 106.2

.421 6 230 110.0

.562 8 235 112.8

.700 10 240 116.01.05 15 250 121.01.40 20 259 126.51.75 25 267 130.92.10 30 274 134.42.46 35 281 139.02.81 40 287 141.33.16 45 292 144.63.51 50 298 147.73.86 55 303 150.64.21 60 307 152.34.57 65 312 155.14.92 70 316 157.75.27 75 320 160.05.62 80 324 162.25.97 85 328 164.86.32 90 331 166.56.68 95 335 168.77.03 100 338 170.07.73 110 344 173.28.43 120 350 177.08.79 125 353 178.69.14 130 356 180.09.84 140 361 182.5

10.54 150 366 185.311.25 160 371 188.511.95 170 375 190.512.65 180 380 193.013.36 190 384 195.214.06 200 388 197.815.47 220 395 201.6

100

10 20 30 40 50 60

200 300 400 500P O U N D S / S Q . I N .

K I L O PA S C A L S ( k Pa )

DEG

REE

S FA

REN

HEI

T

DEG

REE

S CE

NTI

GRAD

E

600 700 800 900 1000

400

500

300

200

10050

0

100

150

200

250

Steam Pressure vs. Temperature

36 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E A P P E N D I C E S / 37

The graph shows the % saving of blowdownwhich may be obtained by better control of theboiler water TDS.

A TDS system will maintain TDS at just belowmaximum allowable levels unlike manualsystems where allowance must be made for asafety factor.

■ Initial average boiler water TDS with manualcontrol: 2000 ppm

■ Final boiler water TDS with automaticcontrol: 3000 ppm

■ Feedwater TDS: 400 ppm■ From the graph the percentage saving of

blowdown is 39%■ Up to 80% of the Blowdown Energy may be

recovered with a Heat Recovery System

Savings by better control of boiler water TDSCalculating the amount of boiler blowdown requiredThe blowdown required as a percentage of the steam generated is:

x100%. Where B = Desired boiler water total dissolved solids (ppm)

F = Feedwater TDS )ppm)

Savings from reduced blowdownFor each 1% reduction in the blowdown rate the % saving in the cost offuel consumed in the boiler is:

Boiler pressure Percentage fuel savings bybar g psig 1% reduction in blowdown rate

7 102 0.19%10 145 0.21%17 247 0.25%25 363 0.28%

ExampleOriginal conditions were: average boiler water TDS 2500 ppm and afeedwater of 300 ppm.

Blowdown rate = x 100% = 13.6%

Conditions were improved by installing a TDS control system andincreasing the amount of condensate return. Final conditions are:average boiler water TDS 3000 ppm and a feedwater TDS of 200 ppm.

Blowdown rate = x 100% = 7.1%

The saving of blowdown is therefore 13.6%–7.1% = 6.5%For a boiler pressure of 10 bar g the saving is 6.5 x 0.21% = 1.37% ofannual fuel bill.

FB–F( )

3002500–300( )

3003000–200( )

1000

Initial average boiler water TDS (ppm)

1500

2000

20002500

3000

3500

Final boiler water TDS (ppm)

2500

3000

10 20 30 40 50 60

Initial average boiler water TDS (ppm)

800600400200

50

Feedwater TDS (ppm)

A P P E N D I C E S / 3938 / T E C H N I C A L S P E C I F I C A T I O N & U S A G E G U I D E

Installation of Topog-E® gaskets in steam boilers

1. Remove old gasket and thoroughly clean the surface on boiler and on cover plate. It may

be necessary to buff each surface. Place new Topog-E® gasket on inspection cover plate,

and make sure that the gasket is pushed down tight on the plate. Do not use any grease,

lubricant or adhesive. When the cover plate is in the boiler and the gasket is in place, make

one last cleaning swipe using a rag wrapped around your finger to ensure the mating

surface in the boiler is clean.

2. Set crab, then center plate in opening and tighten nut enough to give a snug fit. Make it

hand tight then increase pressure on the gasket with a quarter turn of wrench.

3. Gaskets on the bottom of a boiler shell are typically more difficult to install without leaking

because small particles tend to become lodged between the mating surfaces after they have

been cleaned. This can lead to over-tightening of the gasket to stop leakage. It is

recommended to drain the boiler and start over or the gasket’s service life may be shortened.

4. Do not over-tighten as it will over-compress the gasket and shorten its service life. If

gasket leaks while pressure is being built up, tighten only enough to stop leakage.

5. As pressure builds up to operating level in the boiler, the nut and crab will loosen as it

typically takes several days for the gasket to reach its ultimate compression. It is

important to keep the nut at least finger tight until it no longer loosens.

6. Never re-use a Topog-E® gasket!

7. Topog-E® bolt gaskets (when required) should be used with Topog-E® handhole gaskets.

Topog-E gaskets are sold for use in steam, water, air, and other selected applications only.

Recommendations for their use are based on tests believed to be reliable and on actual

customer experience. Since their installation and use are beyond our control we cannot

guarantee the results, whether or not such use is in accordance with directions. We

disclaim any responsibility.

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2

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T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E .T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G - E . T O P O G -

THE TOPOG-E GASKET COMPANY HAS BEEN MANUFACTURING ANDSELLING MOLDED RUBBER GASKETS AROUND THE WORLD FOR OVERFORTY YEARS. WE MAKE GASKETS TO FIT EVERY BOILER INPRODUCTION TODAY, AND OUR GASKETS ARE RENOWNED FOR THEIRQUALITY, DURABILITY, AND EASY INSTALLATION AND REMOVAL.

The purpose of this booklet is to give appropriate information,technical specifications, and guidance, to ensure that yourboiler’s needs are correctly and safely addressed.

The first section focuses on the gaskets themselves, and thesecond section considers issues associated with boilermaintenance.

At the Topog-E Gasket Company, we are proud of our long-standing knowledge of the boiler industry. Our continuingresearch and development work helps us to remain at theforefront of technical advances.

We trust this guide will be helpful when using Topog-E® gaskets,performing boiler maintenance, and conducting education andtraining seminars.

If you require any further advice or clarification, please call yourlocal distributor or log on to www.topog-e.com

Size (inches) Shape Code Type A B C D (unless stated otherwise) 11-1/2 14-1/2 1-1/4 – E Manway 11 15 3/4 – E Manway 11 15 1 3/16 E Manway 11 15 1 – E Manway 11 15 1-1/4 – E Manway 11 15 1-3/8 – E Manway 11 15 1-3/4 – E Manway 11-1/2 15-1/2 1-1/4 – E Manway 11-1/2 15-1/2 1-3/4 – E Manway

11-3/4 15-3/4 1-3/8 – E Manway 11-3/4 15-3/4 1-3/4 – E Manway

11 16 1-1/4 – E Manway 12 15 1 – E Manway

12 15 1-1/4 – E Manway 12 15-1/2 1 – E Manway

12 15-1/2 1-1/4 – E Manway 12 16 1 – E Manway

12 16 1-1/4 – E Manway 12 16 1-3/8 – E Manway

12 16 1-1/2 – E Manway 12-1/2 16-1/4 1-1/4 – E Manway

12-1/2 16-1/2 1 – E Manway 14 18 1-1/2 – E Manway

16 18 1-1/4 – E Manway 18 21 1-1/2 – E Manway

18 24 1-1/2 – E Manway

1-3/4 3-3/4 1/2 – OB Handhole 2 3 1/2 – OB Handhole 2-1/4 3-1/4 1/2 – OB Handhole 2-1/4 3-1/4 3/8 – OB Handhole 2-1/2 3-1/2 1/2 – OB Handhole 2-1/4 3-3/4 9/16 – OB Handhole 2 4 9/16 – OB Bracket 2-1/2 3-3/4 1/2 3/16 OB Handhole 2-3/4 3-1/2 1/2 – OB Handhole 2-3/4 3-3/4 1/2 – OB Handhole 2-7/8 3-7/8 7/16 – OB Handhole 2-7/8 4-3/8 9/16 – OB Handhole 2-3/4 4-1/2 1/2 – OB Handhole 3 4-1/4 1/2 – OB Bracket 2-3/4 4-3/4 1/2 – OB Handhole 3 4 1/2 – OB Handhole 3 4 9/16 – OB Handhole 3 4-1/2 9/16 – OB Handhole 3-1/4 4-1/4 9/16 – OB Handhole 3 5 9/16 – OB Handhole 3-1/4 4-1/2 1/2 – OB Handhole

Size (inches) Shape Code Type A B C D (unless stated otherwise) 3-3/4 5-1/4 5/8 – E Bracket

3-1/2 5-1/2 5/8 – E Bracket 4 4-3/8 1/2 – E Handhole

4 5-1/2 3/4 – E Handhole 4-1/2 5-1/2 5/8 – E Handhole

4 6 5/8 – E Handhole 4 6 3/4 – E Handhole

4-1/4 5-1/8 3/8 – E Handhole 4-1/2 6-1/2 9/16 – E Handhole 4-1/2 6-1/2 1-1/4 – E Handhole 4-3/4 6-5/8 3/4 – E Handhole

5 6 5/8 – E Handhole 5 7 3/4 – E Handhole

5-3/4 7-1/4 3/4 – E Handhole 6 8 3/4 – E Handhole

6 8 1 – E Handhole 6 9 1 – E Handhole

6 10 5/8 – E Handhole 6 10 1 – E Handhole

7 9 3/4 – E Handhole 7 10 1-1/2 – E Handhole

7-1/2 10-1/4 3/4 – E Handhole 7-1/2 11-1/2 1 – E Manway

7-7/8 11-3/4 1 – E Manway 8 10 1 – E Manway

8-5/8 12-1/2 1 – E Manway 8 11 1 – E Manway

9 12 1 – E Manway 9 14 1-1/4 – E Manway

9-1/2 14 1-1/8 – E Manway 9-3/4 14-1/2 2 – E Manway

9-3/4 14-3/4 1-1/4 – E Manway 9-1/2 15-1/2 1 – E Manway 9-15/16 15-15/16 3/4 – E Manway 10 14 1 – E Manway

10 14 1-1/2 – E Manway 10-1/2 14 1-1/4 – E Manway

10-1/2 14-1/2 1-1/4 – E Manway 10-1/2 14-1/2 1-3/8 – E Manway

10 15 1-3/8 – E Manway 10-1/2 15 1-1/4 – E Manway

10-1/2 14-1/2 1-3/4 – E Manway 10-3/4 14-3/4 1-1/4 – E Manway

10-5/8 14 1-5/8 3/16 E Manway 10 16 5/8 – E Manway 10 16 1-1/4 – E Manway 11 14 1-3/8 – E Manway 11 14 1-1/4 – E Manway 11 14-1/2 1 – E Manway 11 14-3/4 1-1/2 – E Manway

Elliptical – ‘E’ Size (inches) Shape Code Type A B C D (unless stated otherwise) 3-1/4 4-1/2 9/16 – OB Handhole

3-1/4 4-3/4 5/8 – OB Handhole 3-1/4 4-3/4 1/2 – OB Handhole

3-1/2 4-1/2 9/16 – OB Handhole 3 4-3/4 9/16 – OB Bracket

3-3/8 4-1/4 3/8 – OB Handhole 3-1/2 5 9/16 – OB Handhole 3-1/4 5-1/4 9/16 – OB Bracket 3-1/2 5-1/2 1/2 – OB Handhole

3-1/2 5-1/2 5/8 – OB Handhole 3-5/8 5-5/8 7/16 – OB Handhole

3-5/8 5-5/8 9/16 – OB Handhole 3-5/8 5-5/8 1 – OB Handhole

4 5 5/8 – OB Handhole 4-1/2 5-1/2 5/8 – OB Handhole

4 6 5/8 – OB Handhole 4-1/2 6 5/8 – OB Handhole

4-1/2 6-1/2 5/8 – OB Handhole 4-1/2 10-1/4 3/4 – OB Handhole

5 6-3/4 1 – OB Handhole 5 7 5/8 – OB Handhole

5 7-1/2 1 – OB Handhole 8-5/8 12-1/2 1 – OB Manway 10-1/2 14-1/2 1-5/16 – OB Manway 11 15 1-1/4 – OB Manway 11-5/8 15-5/8 1-1/4 – OB Manway 12 16 1-1/4 – OB Manway

12 16 1-1/2 – OB Manway

Inner D Outer D C D 1-3/8 2-5/16 – 5/16 R Handhole 2-7/8 3-5/8 – 1/8 R Handhole 2-15/16 3-15/16 – – R Handhole 3 3-5/8 – 3/16 R Handhole 3 3-3/4 – – R Handhole 3 4 – – R Handhole 3-1/4 4 – – R Handhole 3-1/2 4-3/16 – 3/16 R Handhole 3-1/2 4-1/2 – – R Handhole 3-1/2 5 – – R Handhole 3-1/2 5-1/2 – – R Handhole

3-11/16 4-1/2 – 3/8 R Handhole 4 4-3/4 – – R Handhole

4 5 – – R Handhole 4 5-1/4 – 3/16 R Handhole 4-1/4 5-1/16 – – R Handhole 4-1/2 5-1/2 – 3/16 R Handhole

4-3/4 6-3/8 – – R Handhole

Inner D Outer D C D 5 6 – – R Handhole

5-1/4 8 – 5/16 R Handhole 5-7/16 7-9/16 – 5/16 R Handhole

6 7 – – R Handhole 6 7-1/2 – – R Handhole 10-3/4 13-3/8 – 1/8 R Manway 12-3/4 16-1/8 – 1/8 R Manway

15-5/8 19-1/2 – – R Manway 17 20 – – R Manway

17-1/2 19-3/4 – 1/8 R Manway 17-5/8 19-1/2 – – R Manway

19 21-1/4 – – R Manway 19 21-5/8 – – R Manway

19 21-7/8 – – R Manway 19 21-7/8 – 13/16 R Manway

19 22 – 1/8 R Manway 19-1/4 21-5/8 – 1/8 R Manway 19-1/4 21-7/8 – 1/8 R Manway 19-1/2 22-1/2 – 1/8 R Manway

20-1/4 22-1/2 – 1/8 R Manway 20-3/8 22-7/8 – 1/8 R Manway

Size (inches) Shape Code Type A B C D (unless stated otherwise) 1-1/2 3-3/4 – R, 4 holes Flange

2 3-1/2 – S, 4 holes Flange 7-3/8 7-3/8 5/8 – S Handhole

2 6 1-1/2 Rect. Handhole 2-13/16 16-7/8 1-1/16 3/16 Rect. Handhole

3-3/4 8-1/2 1/2 Rect. Handhole 4-1/2 6 1/4 – Rect. Handhole

6-1/4 9-3/4 5/8 – Rect. Handhole 3 4 9/16 – K Handhole

3-3/8 3-3/4 1/4 1/8 D 3-3/8 4-1/4 1/4 – D Handhole

3-1/2 4-1/2 1/4 – D Handhole 4 5 1/2 – D Handhole

4-1/4 5-1/4 13/32 – D Handhole 3-1/2 4-1/2 7/16 – P Handhole

3-3/8 4-3/8 1/2 – P Handhole 3-5/8 4-3/4 1/2 – P Handhole

4 5 1/2 – P Handhole 4 5 9/16 – N.P. Handhole

4 5 5/8 – W.P. Handhole 4-1/4 5-1/8 1/2 – SPU.P Handhole

4-1/2 5-1/8 1/2 – P Handhole 5-1/4 5-1/4 3/8 – SPS Handhole 7-7/16 7-7/16 9/16 – SPS Handhole

OBround – ‘OB’ flat sides

Special shapes

Round – ‘R’

Be sure you have the right size and shape gasket for each cover plate – This is very important!

For quick, accurate identification, the size and shape are clearly molded into each Topog-E® gasket.

Make sure the gasket installer reads the Topog-E Installation Instructions before installing Topog-E® gaskets!

Standard thickness is 1/4” unless otherwise noted under column D.

www.topog-e.com

Size (inches) Shape Code Type A B C D (unless stated otherwise) 1-7/8 2-1/2 7/16 – E Handhole 1-3/4 3-3/4 3/8 – E Handhole 2 3 3/8 – E Handhole

2 4 1/2 – E Handhole 2-1/4 3-1/4 1/2 – E Handhole

2-1/4 3-1/2 1/2 – E Handhole 2-1/4 3-3/4 1/2 – E Handhole 2-1/2 3-1/4 3/8 – E Handhole 2-1/2 3-1/2 1/2 – E Handhole 2-3/4 3-1/2 3/8 3/16 E Handhole 2-1/2 3-3/4 3/8 3/16 E Bracket 2-1/2 4 1/2 – E Handhole 2-3/4 3-1/2 1/2 – E Handhole

2-1/2 3-3/4 1/2 – E Handhole 2-3/4 3-3/4 5/8 – E Handhole

2-3/4 3-3/4 1/2 – E Handhole 2-7/8 3-7/8 1/2 – E Handhole 3 3-3/4 1/2 – E Handhole 2-3/4 4-1/2 5/8 – E Handhole

3 4-1/4 5/8 – E Bracket 3 4 5/16 – E Handhole

3 4 1/2 – E Handhole 2-3/4 4-1/4 1/2 – E Bracket

3 4 5/8 – E Handhole 3 4 3/4 – E Handhole

3 4 1-1/2 – E Handhole 3 4-1/2 1/2 – E Handhole

3 4-1/2 5/8 – E Handhole 3 5 9/16 – E Handhole

3-1/4 4-3/4 9/16 – E Bracket 3-1/4 4-1/4 1/2 – E Handhole

3-1/4 4-1/4 3/4 – E Handhole 3 4-1/2 3/4 – E Bracket

3-1/4 4-1/2 1/2 – E Handhole 3-1/4 5 9/16 – E Handhole

3-3/8 4-3/8 7/16 – E Handhole 3-3/8 4-3/8 9/16 – E Handhole

3-1/2 4-1/2 7/16 – E Handhole 3-1/2 4-1/2 1/2 – E Handhole

3-1/2 4-1/2 5/8 – E Handhole 3-1/2 4-1/2 3/4 – E Handhole

3-1/2 4-1/2 1-1/2 – E Handhole 3-1/2 5 1/2 – E Handhole

3-1/2 5 3/4 – E Handhole 3-3/4 4-3/4 9/16 – E Handhole

3-3/4 5-1/2 9/16 – E Handhole 4 5-1/4 9/16 – E Bracket

4 5 5/8 – E Handhole

Molded Rubber

Gaskets

Topog-E® Series 180Product Catalog 2015

Valid from 02/01/15

“They are the best gaskets I have ever

used ...snug, tight and NO leaks.”

– Hospital

“My boiler loves your gaskets, it never

leaks a drop and they are easy to put

on. I heartily recommend them to

every boiler.” – Dry Cleaner

“Our boiler inspector likes your

gaskets after seeing the results, he

now recommends them to other boiler

operators.” – Hospital

“None better!” – Industrial Plant

““These gaskets gave perfect results

on a mighty tough test installation.

I will certainly recommend them

at every opportunity.” – Water

Conditioning Service

The Topog-E® Gasket Company has been manufacturing

rubber gaskets for steam, air and water applications

since 1956.

The company was started by Frank Maxwell Thomas, a

combustion engineer born in Batavia, New York. Frank

formed Thomas Engineering in 1948, selling steam boilers,

hot water heaters and combustion engineering services.

The company’s move into rubber gaskets was prompted

by a customer’s question to Frank: “why couldn’t a boiler

gasket be made out of rubber, then it would not leak?”

The fibrous gaskets used at the time frequently leaked,

which lead to lengthy and expensive downtime while

the gasket was removed and the shell and plates were

cleaned by chiselling and buffing.

Frank set to work, and Thomas Engineering gave birth to

the Topog-E® Gasket Company. Frank began with a jigsaw

and sheet rubber, and he named his invention Topog-E

®(from Topography and Engineering) because the gasket

was able to conform to the topography of the mating

surfaces.

Having established a compound that worked in the hostile

steam environment, he hired a rubber technologist to

refine the proprietary mixture. He created Topog-E’s own

rubber laboratory and acquired manufacturing equipment

to begin production of the first molded rubber boiler

gaskets.

Today, Topog-E still mixes its own compounds and

manufactures the gaskets on site, making approximately

1 million gaskets per year in over 300 different stock

sizes. Two generations on, Frank’s family is still running

1224 North Utica . Tulsa . Oklahoma 74110

T: 918 587-6649 . F: 918 587-6961 . E: info@topog-e.com

W: www.topog-e.com

Y O U R L O C A L T O P O G - E ® D I S T R I B U T O R

10 16 1-3/4 – ET Manway

8-3/4 14 2-1/4 E, w 4 bolt holes Manway

3-7/8 13-3/8 1-3/16 1/8 OB Flange

Size (inches) Type OD x OD x thickness 21-1/2 x 21-1/2 1/8 Sheet 3/16 Sheet

1/4 Sheet 24 x 24 1/8 Sheet 3/16 Sheet 1/4 Sheet 27-1/2 x 27-1/2 1/8 Sheet 3/16 Sheet

1/4 Sheet 30 x 30 1/8 Sheet

3/16 Sheet 1/4 Sheet

Square gaskets to fit 5/8” and 3/4” bolts Square gaskets to fit 1” bolts Topog-E® bolt gaskets (when required) should be used with Topog-E® handhole gaskets.

Rubber gauge glass gaskets for 1/2”, 5/8” and 3/4” gauge glass

Gauge glass 5/8” Red line 3/4” Red line 1/2” Clear 5/8” Clear

NOTES: n Standard thickness is 1/4” unless otherwise noted under column D.n All prices are for Topog-E® Series 180 Gasket Material (refer to separate

Material Specification sheet for more information). n Prices are F.O.B. Tulsa, Oklahoma 74110. n Bracketed gaskets are not stock molded sizes, however, the first stock size

can often be used on plates designed for the bracketed size. n We have upgraded our ability to quickly die-cut gaskets in special shapes & sizes from our Series 180 sheet material.n Topog-E® gaskets can be made from other materials and in special sizes and

shapes upon request. Disclaimer: Topog-E® gaskets are made and sold for use in steam, water, air, and other selected applications only. Our recommendations for their use are based on tests believed to be reliable and on actual customer experience. Since their installation and use are beyond our control, we cannot guarantee the results, whether or not such use is in accordance with instructions. We disclaim any responsibility.

Topog-E sheet material

D

A

B

C

Elliptical – E

When ordering, be sure to state the two inside dimensions (A & B), flange width (C), thickness (D), and shape (E, OB, etc.).

OB Round – OB

Round – R

Rectangle – Rect.

Diamond – D

Pear – P

Square – S

Special Square – SPS

Elliptical Turtle – ET

Gauge glass products

Bolt gaskets

© Copyright 2015 – TOPOG-E GASKET COMPANY

This information is intended to be used by authorized Topog-E Distributors and

customers only. Any reproduction and transmission of this information in any form or

by any media without the express written consent of the Topog-E Gasket Company is

prohibited.

Shape Code Special shapes

®