Presented by: Ron FrisardAW Chesterton Company

Fundamentals of Valve Packing Installation

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Ron Frisard graduated from Northeastern University in Boston with a degree in Mechanical Engineering Technology in 1989. Before joining Chesterton Ron worked for Newport News Shipbuilding designing propulsion systems for aircraft carriers. He has worked for the A.W. Chesterton Company for the last 25 years in all facets of Mechanical Packing. Some of his accomplishments include developing simplified valve live loading system, creating a 24/7 data acquisition pump packing test stand that has helped develop successful packing products, and revamping the pricing model for packing by the box.Ron has held positions in Application Engineering, Research and Development, and Marketing and Global Training. He is currently responsible for packing, gasketing, and live loading product field management. Ron has presented at many conferences including the Electric Power Research Institute (EPRI), the American Society of Mechanical Engineers (ASME), and Valve World in Europe.

Presenter Bio

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“Managing leak documentation is great but we really need to focus on stopping the leaks before they need to be managed”

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With more complex packing that performs to meet lower emissions standards, correctly installing packing will dramatically affect overall LDAR performance

Valve Packing Performance Effects on LDAR

“Common Sense is not so common”

- Voltaire, Dictionnaire Philosophique

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“Time and effort during valve packing installation is the best chance to reduce LDAR issues”

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<~2000 Free for all Each packing manufacture was testing on own

protocols ( media/cycles/thermal cycles)

~2000 – 2006 Independent testing Refineries started to create their own protocols that

had to be completed by independent labs

>2006 Standardizing testing takes hold API / Taluft / ISO create standard test protocols

Valve Packing Emissions Testing Timeline

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Measuring

Inspection

Installation

Consolidation

Continuous Improvement

Training

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Correct measurements are key Recording measurements are

vital to not have to repeat over and over

OEM valve drawings rarely have stuffing box dimensions

Measuring

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Identification ID Valve Data (man/model/etc) Stem ID / Box OD Stuffing Box Depth Stud Diameter (# of Studs) Gland Nose Length Operating Conditions

What to MeasureMeasuring

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“Accuracy of observation is the equivalent of accuracy of thinking”- Wallace Stevens

Calibration Training

AccuracyMeasuring

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Check dimensions Best chance to check up stream

mistakes Confirm depth – all rings removed

Inspect bolts For LDAR, consider replacing studs

to get accurate loading

Inspection

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Best chance to see valve issues is looking at packing Extrusion Wrong size Cutting Wrong packing

Temperature issuesChemical compatibility

PackingInspection

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Gland nose length Ratio of nose length / cross section is not

standard Possible bottoming out gland before leak

sealing limits Stem Finish Check for angled valve bottom

Square packing not designed for angled stuffing boxes

Fix problem with junk ring below bushing

Other ConcernsInspection

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5 rings only need to seal More rings less sealing Poor load distribution of load Major consolidation and loss of gland

load Carbon standard for retrofitting

Thermal growth better then metals

Bushing (If Needed)Installation

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Best solution: Supply cut rings Take out major cause of failure

If cutting own rings: Use a mandrel to cut rings Use a sharp knife Use a forceful cutting motion Cut each ring separately Check each ring with Mandrel after

cutting

Cutting RingsInstallation

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Insert the first ring into the stuffing box use a tamping tool to firmly seat the

packing against the bottom of the box (or bushing).

Packing rings are specifically designed to fit snuggly in to obtain optimum sealing for lowest possible emission rates.

Installing RingsInstallation

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Apply anti-seize lubricant to gland stud threads, nuts, and hardened washers Note Anti-seize COF (nut factor) to be

taken into consideration of torque calculation

Hardened washers should be utilized under the gland nuts (reference ASTM-F-36)

Bolt LubricationInstallation

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Get formula for torque from Packing manufacture (not all the same)

Using a calibrated torque wrench Torque alternately between gland

nuts to not cock the gland which could cause valve stem scoring or uneven loading of the packing set

TorqueInstallation

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Major step to ensure proper leveling of gland load Actuate the valve multiple times Retighten with torque wrench If any movement of the nuts

(consolidation), repeat actuation steps until no movement at the recommended torque.

The larger the packing cross section, the greater the consolidation

Consolidation

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Changing a plant’s culture Fact based Being part of the solution Savings on time Reduce wrong product installed Streamlining storeroom

Continuous Improvement

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Lower packing leakage rates (LDAR) Cross functional team

Maintenance, Engineering, I&C, etc Capture ALL packing failure Training all groups to capture packing

coming out of valves Fill out form to track Look for ROOT CAUSE!!

GoalsContinuous Improvement

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Utilizing a blended strategy Groups (Engineering, I&C, LDAR, and

Maintenance) Type of training (Classroom & hands

on) Focus on contractors / outages

Training

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Measuring

Inspection

Installation

ConsolidationContinuous Improvement

Training

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Remember, proper installation is the best chance for successful packing

life

Any Questions?

You can Visit www.chestertonstationary.com for

more information

Questions