Hydrogen systems are notoriously challenging due to the unique properties of hydrogen: its small molecular size, high flammability and corrosive nature. In a recent project, KLINGER Australia was tasked with developing an oversized gasket to effectively seal a hydrogen cylinder. The effort required not only the precise design and fabrication of a high-performance gasket but also overcoming the logistical challenges of producing and transporting a massive gasket—nearly 4 meters in diameter.
Maintaining the gasket’s integrity at every stage was crucial to ensuring the success of the project.
Oversized gaskets refer to gaskets that exceed the limits of conventional manufacturing and transportation. They demand special considerations including:
- Customised Engineering design
- Specialised manufacturing equipment
- Experience team coordination
- Tailored transport solutions
From Factory Floor to Final Destination
Starting with the Right Materials
To meet the unique requirements of this project, our engineers worked closely with the client to understand the application’s demands and proposed a gasket design using materials specifically suited for hydrogen systems.
- 321 Stainless Steel Core: Offers exceptional resistance to high temperatures and corrosion, ideal for demanding hydrogen applications.
- Mica Facing: Withstands extreme heat (up to 1000°C) and provides excellent chemical resistance, ensuring durability and sealability.
After presenting the proposed solution, including the design, materials and their performance capabilities, the client approved the selection.
Precision Engineering to Meet Exacting Standards
The oversized nature of this gasket posed unique challenges, requiring precision at every stage:
- Core Cutting: For a large gasket like this, the ring is segmented into pieces to fit onto sheets of material. Once the design is finalised, the nesting pattern is transferred to the laser for cutting precise dimensions and smooth, burr-free edges.
- Welding: The parts are then sent to the welding stage, where the welder joins the segments to form the complete ring. After welding, the joints are ground smooth to ensure uniformity before moving on to the machining phase.
- Kammprofile Design Creation: Profiling machines cut grooves into both sides of the core carefully controlling pitch and depth to enhance sealing performance.
- Mica Facing Preparation and Application: Knife-cut mica sheets are prepared and applied to the ring using adhesive bonding to achieve secure and durable attachment.
- Finishing and Quality Control: The gasket undergoes inspection for dimensional accuracy and rigorous testing to ensure high-temperature and pressure resistance, meeting performance standards.
Solving the Transportation Challenge
Transporting an oversized gasket posed as much of a challenge as manufacturing it, demanding smart logistics solutions:
- Custom Sloped Crates with an A-Frame Configuration: A specially designed crate stabilised and protected the gasket during transit. The upright A-frame configuration optimised space, eliminated the need for wide-load trucks, minimised movement and significantly reduced the risk of damage.
- Securement: The finished gasket was carefully transferred to the custom crate and secured with metal straps. Rubber inserts were used in the straps to prevent damage and ensure the gasket remained stable and protected during transit.
- Team Coordination: A team of operators managed the handling and loading process, ensuring the gasket was transported safely and without compromise to its structure.
The most challenging aspect was the size of the gasket. Maneuvering it required a team of 6-8 people working in perfect coordination to safely turn the rings over and move the gasket to the next process. It was a true test of teamwork and precision, but luckily, we have a team that has been working together for years, and their experience made all the difference
Keep things flowing no matter the scale of the task
With over six decades of experience in Australia, we’ve built strong partnerships across diverse sectors, designing, manufacturing and delivering solutions that ensure processes run smoothly and efficiently.
From intricate manufacturing projects to complex logistics, no challenge is too big or too complex for us to tackle. Whether it’s creating a custom solution, overcoming production hurdles or solving logistical puzzles, we’re committed to helping you keep things flowing seamlessly.
