Winter 2020
No.38

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● ＴｅｃｈｎｉｃａｌＰｅｐｅｒｓ● Introduction to Valqua Technology News
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● ＴｅｃｈｎｉｃａｌＰｅｐｅｒｓ

Representative Director, Chairman & CEO
Toshikazu Takisawa

Director, Managing Executive Officer CTO & CQO
Mutsuo Aoki

Influence of Bolt Tightening Methods on the
Sealing Performance of Large Diameter Bolted
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Pipe Flange Connections・
Evaluation of the Compression methods on the
Sealing Performance of Gland Packing・
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・11

● ＴｅｃｈｎｉｃａｌＰｅｐｅｒｓ

Comparison of Semi-Metallic Gasket s Performance
・・・15
and Introduction of Kammprofile Gasket Series・● ＰｒｏｄｕｃｔＩｎｔ
ｒｏｄｕｃｔｉｏｎｓ

Introduction of High-speed Opening and Closing Cylinder Valve・・・・19● ＰｒｏｄｕｃｔＩｎｔ
ｒｏｄｕｃｔｉｏｎｓ

Development of Spray BallTM for Tank Cleaning・・23● Recent Technology News Back Issues・・・29

Greetings
Toshikazu Takisawa
Representative Director, Chairman & CEO
VALQUA, LTD.

Greetings from the early spring of the second year of Reiwa era.
We would like to sincerely thank our readers for reading our magazine
on a regular basis.
The new era of“Reiwa”began on May 1st last year in the Japanese calendar.
In the first New Year of Reiwa, as concerns over a slowdown in the global economy are increasing as
market conditions are reflected in the deterioration of U.S.-China relations and the effects of the newvirus, and in Japan, we also saw a decline in domestic demand due to the increase in the consumption
tax and the scars of natural disasters. Although there are signs of a bottoming out in semiconductor
demand and automobile sales, which have continued to decline, the business environment in recent
years is constantly being exposed to drastic change. For companies to survive in this rapidly changing
business environment, the ability to quickly provide solutions to market issues should be important.

Winter 2020

Our Group has positioned last year as the first year of the New Valqua Era and we have made astrong determination to leap forward as an H&S company. We are determined to transform ourselves
into a company that aims to build a mindset and business model that pursues the creation of customer
value, including moving from hardware only to services. Last year, to clearly communicate our resolve
both inside and outside the company, we built a new management system and, with our commitment

No.38

to“Value”and“Quality”, which are the origins of our company name, we have been working tostrengthen our system to focus on creating innovation and providing customers with new value-added
products and services to provide solutions to the various challenges that may arise in the future fromthe steps required by the global market.
Against this background, the Company’s eighth medium-term management plan“New Valqua Stage
Eight（NV・S8）,”which started in FY2018, ended in FY2019. From FY2020, we have decided to build
new activities to achieve business growth toward our 100th anniversary under a new medium-term
management plan. In this new plan, we intend to provide customers with solutions that meet thechallenges of the global market by implementing more innovative activities based on the H&S concept.
In addition to providing“safety and security”to customers through seal engineering services, afundamental issue for our company, in response to the urgent global issue of environmental impact, we
are working to solve issues related to sustainability in a broad sense by using the technical solutions
we can provide, and we intend to contribute to sound and sustainable growth of a diverse society inline with the United Nations’SDGs（Sustainable Development Goals）.
We have the Tokyo Olympics in this summer and this is the first year of change at our company
which is the beginning of a new era of Reiwa. We look forward to your continued support this year
and wish all our readers the best in the coming year.
1Introduction to Valqua Technology NewsNo. 38 Winter 2020

We sincerely wish everyone a happy spring of the second year of Reiwa era. Thank you for regularly
reading the Valqua Technology News.
In the era of Reiwa, interest and expectations for the role of innovation for corporate growth are
increasing. In the changes brought by technological innovations such as IoT and AI, there is atransition that requires a single product technology development solution to be combined with othertechnology solutions, and that complex and diversified new value-added products and services beoffered to the market. In addition, in technology development to support this change, creating resultsthat pursue efficiency and speed, and establishing an ecosystem of technology development thatorganically connects a wide variety of technology development activities that are being deployedglobally is essential, and such is being implemented under the keyword of open innovation involving
industry, government, and private sectors.

Against this background, in this issue of Technology News, we look ahead to the introduction of nextgeneration technologies that we are promoting, firstly focusing on the core technology of sealengineering, which is the base, and prepared an essay introducing our technology and an introduction
to our core products. As for the technical essay, it is an analysis of the effect of the tightening
method on the sealing characteristics of large-diameter flanged fasteners, consideration ofcompression behavior due to gland packing tightening, and performance evaluation of semi-metallic
gaskets that readers can refer to for safety and security of their plants. Furthermore, as for the
introduction to our products, we take up the quick opening and closing cylinder valve and the newly
developed cleaning Spray BallTM , the usefulness of which has been once again recognized in themarket, and provide useful information for customers in future product selections.
Thank you for your patronage and we hope you will continue to enjoy the Valqua Technology News
this year.
Director, Managing Executive Officer CTO & CQO

Mutsuo Aoki
2

Winter 2020

In this trend, we have taken various measures in our mid-term business plan NV・S8, which began in
2018, to keep up with the times. In particular, in the previous year, we opened the Valqua Advanced
Materials Technology Research Laboratory of in the National Institute of Advanced Industrial Scienceand Technology and promoted the creation of a system that utilizes technologies from startup
companies, such as those in Silicon Valley. In the new medium-term management plan beginningfrom this year, using these new technological solutions, we will incorporate cutting-edge newmaterials, sensing technology, and IoT and AI technology into core technology areas such as sealing
technology that we have accumulated since our founding, and resin processing technology such as
fluororesin, as well as strengthen our technology development activities to provide H&S products inareas that encompass everything from hardware products to services with solutions that customers
truly seek. Furthermore, in order to provide cutting-edge technology solutions to the market as highquality products, we are promoting activities that include the introduction of RPA for production
technology innovation.

No.38

Influence of Bolt Tightening Methods on the
Sealing Performance of Large Diameter Bolted
Pipe Flange Connections
specification”was published in China. However, the

1. Introduction

index used in these standards is the final bolt axial

Gasketed pipe flange connections are used in large

force and does not deal with the actually required

numbers in pressure vessels and pipe connections insealing performance of the flange connections.

various industries. It is known that the sealing

In Valqua Technology News Vol.37 in the previous

performance of the pipe flange connections depends

report, the effect of tightening methods of ASME PCC-

not only on the gasket characteristics but also on the16）and JIS B 22517） using ASME class 150 4 inches

tightening method. According to The High Pressure

small diameter and ASME class 300 24 inches large

1）

Winter 2020
No.38

Gas Safety Institute of Japan（KHK） , it is reported

diameter flange connections sealing performance wasthat about 67% of leakage accidents from gasketed

examined and it was clarified that both of them arepipe flange connections are caused by improper bolt

appropriate methods to exhibit adequate sealing

tightening method. One of the factors of tightening

perfromance 8）. However, although ASME PCC-1 6）

failure is the elastic interaction occurring during bolt

shows several bolt tightening methods, the effects oftightening. This is a phenomenon that affects eachthese tightening methods on the sealing performanceother when a large number of bolts are tightened.

of the connections have not been studied.

Each axial bolt force falls below the target bolt axial

This reportaims to investigate the effects of theforce, and individual bolt axial forces vary. As a result,tightening methods combined with Alternative #1, #2,

an appropriate bolt axial force cannot be achieved, theand #3, which are newly added to ASME PCC-16） bygasket compressive force required for sealing cannot

using ASME class 300 24-inch flange connections, onbe obtained and leakage may occur. It is difficult tothe variation of bolt axial force, sealing performances,

reduce the effects of this elastic interaction to zero,bolt tightening times, and wrench moving distances.

and measures are being taken to reduce the effects,

In this report, the test was conducted using our high-such as increasing the number of circular tightening

performance gasket No. GF300 and expanded graphite

cycles or performing cross-tightening. However, all of

filler spiral gasket No. 6596V.

them are based on experience and it is hard to saythat sufficient technical studies have been done2）-5）.
Under these circumstances, various standards have

2. Test method

recently proposed bolt tightening methods for2-1）Test equipment

achieving an appropriate bolt axial force. In the UnitedFigure1 shows the pipe flange connection with aStates, ASME PCC-1 6） Guidelines for Pressure

gasket used in this paper. The dimensions are 24

Boundary Bolted Flange Joint Assembly was proposed

inches, which is the largest nominal diameter in thein 2000 and revised in 2013 and 2019. In Japan, JIS B

ASME standard, the pressure rate is class 300, the7）2251 “Flange joint tightening method”was issued inshape is W/N, the seat is RF, and the material is2008, and in 2018,“Flange method mounting technical

SUS304. It is known that the mechanical behavior of3

Technical Papers

the flanged connections changes depending on theσg
T＝K N Agd （2）presence or absence of the pipe. In thisreport, we usedequipment with a pipe of about 800 mm to study

whereunder conditions close to the actual equipment.

T：Torque,［N・m］

The bolts are made of SNB7, and 24 hexagon bolts of

K：Nut factor,（=0.135）

size M39 are used. Two strain gauges are attached toσg：Target contact gasket stress,［MPa］

each bolt body so that the axial force of all bolts can be

Ag：Contact gasket area,［mm2］measured. The strain gauge of each bolt has been

N：Number of bolts,［pcs］

calibrated in advance, and molybdenum disulfide has

d：Bolt nominal diameter,［m］

been applied to the thread and seat of the bolt and nut.
Helium gas was used as the test gas, and the internal

In the experiment, the bolt axial force and the flangepressure was 2 MPa. The leakage amount of the flange

clearance are measured for each tightening cycle.

connection was measured by a pressure drop method.
We measured the change in pressure with a pressuregauge and calculate using the following equation（1）.
MV
T1
L=1atm×ρtRT c P1− T P 2 （1）
1
2

（

）

where

Winter 2020

L：L
 eakage per outer circumference of gasket,［Pa·m3/（s·m）］
M：Molar mass,［mg/mol］
V：Inner volume of pipe flange connections,［ml］
ρ：Density of test gas,［mg/ml］
t ：Measurement time，［s］
R：Gas constant （=8.314）,［J/mol·k］，

Figure1

Experimental setup of 24”pipe flange connection

No.38

T1：Absolute temperature at the start of test,［K］
T2：Absolute temperature at the end of the test,［K］
P1：Absolute internal pressure at the start of the test,［MPa］
P2：Absolute internal pressure at the end of the test,［MPa］
c：Gasket contact outer circumference,［m］
atm：Standard atmospheric pressure（=0.101325），［MPa］
Figure2 shows an image of the work of tightening thepipe flange connection body. Bolt tightening is
performed using a torque wrench with the target
torque. Target gasket surface pressure was 40 MPa

Figure2

Image of tightening

Table1 Target torque, target axial bolt force and contact gasket stress
Size of pipe flange connection

Class300 24B

GasketNo.6596V

No.GF300

and the target torque value T was determined from

Suggested contact gasket stress［MPa］

50

35

Target contact gasket stress［MPa］

40

25

the following equation（2）. Table 1 shows the target

Target axial bolt force［kN］

98.4

85.6

gasket stress and torque.

Target torque［N·m］

520

451

for gasket No. 6596V and 25 MPa for gasket No.GF300

4

Influence of Bolt Tightening Methods on the Sealing Performance of Large Diameter Bolted Pipe Flange Connections

2-2）Test gasket

3-1）Tightening method JIS B 22517）

The gasket dimensions used in this paper φ612×φ772

In JIS B 2251 flange joint tightening method 7）,

×t3.0 for No.GF300 and φ603.2×φ628.6×φ685.8×φ717.6

paragraph 4b）states that "if the number of flange

×t4.5 for No.6596V. Both are ASME class 300 24-inch

bolts is 12 or more, 110% of the specified tightening

diameter dimensions.

torque shall be the target tightening torque. In thisstudy, the measurement and examination are
performed when the target torque is set to 110% in

3. Tightening method

addition to 100%. 5.3b）Section 4）states that when a

In this paper, we compared the variation of bolt axial

spiral-wound gasket is used, the gasket width is soforce, sealing performance, and tightening time of thenarrow that one-sided tightening is likely to occur. To

flange connection under seven types of bolt tightening

prevent this, tighten all bolts at the end of star pattern

methods.

by 50% of the target tightening torque, and one round

Table2 shows each tightening method, and the outlineof tightening is performed by clockwise orof each tightening method is described below.

counterclockwise tightening methods. For this reason,

Table2Tightening methods

Target Torque

Winter 2020

No.6596V
JIS B 2251 110%

110%
No.GF300

No.38

No.6596V
JIS B 2251 100%

100%
No.GF300

ASME
Legacy

5

100%

ASME
Alt.#1

100%

ASME
Alt.#2

100%

ASME
Alt.#3100%

3 Rounds

100%

Bolt tightening methods

Gaskets

Step 1

Step 2

Step 3

Step 4

Number of bolts

4

24

24

24

Rounds4

1

6

2

PatternStar

Circular

Circular

Circular

Number of bolts

4

24

24

Rounds4

62

PatternStar

Circular

Circular─

Number of bolts

4

24

24

24

Rounds4

1

6

2
CircularPatternStar

Circular

Circular

Number of bolts

4

24

24

Rounds4

62

PatternStar

Circular

Circular

Total
232
bolts

208
bolts

232
bolts

─

208
bolts

─

216
bolts

Number of bolts

24

24

24

Rounds333PatternStar

Circular

CircularNo.6596V
No.GF300

Number of bolts

4

16

24

24

Rounds2

1

1

3

Pattern

Star

Star

Star

CircularNo.6596V
No.GF300

Number of bolts

4

16

24

24

Rounds

2

1

1

3

Star

Circular

─

─

108
bolts

─

─

72
bolts

No.6596V
No.GF300

No.6596V
No.GF300

No.6596V
No.GF300

Pattern

Star

Star

Number of bolts

424Rounds3

4

PatternStar

Circular

Number of bolts

24

Rounds3

Pattern

Star

─

120
bolts

120
bolts

Technical Papers

the tightening method of No.6596V is different fromsheet gasket of No.GF300. In addition, in JIS B 22517）,

4. Experimental results

additional tightening was proposed in some cases, and

4-1）Gap distribution between flange faces

the retightening was also carried out in this study.

Figure3 shows the gap distribution between the7）

A major feature of the tightening method according

flange when tightening by seven methods. The results

to JIS B 2251 is that only four bolts（when the number

for the installed gasket No.GF300 are shown by solidof bolts is 24 or less）are temporarily tightened first,

lines, and those for No.6596V are shown by broken

and in the final tightening, all bolts arelines. When the gasket was No.GF300, the effect of thecircumferentially tightened. Since the final tightening

tightening method was minor. On the other hand, in

is a simple circular tightening, it can be expected tothe case of No. 6596V, almost the same results werereduce time and prevent mistakes such as forgetting

obtained with the methods based on the standards of

to tighten.

JIS B 22517） and ASME PCC-16）, but with the 3 rounds
method, the gap was slightly large and the compression3-2）Tightening method ASME PCC-1

6）6）amount was small.

7）

In ASME PCC-1 , unlike JIS B 2251 , the tightening
method does not change depending on the gasket type.
This study covers Legacy, which has been proposed
previously, and Alternatives #1, #2, and #3, which

Winter 2020

have been newly added since 2013.
Legacy is a method of diagonally tightening all bolts
and is the most widely used tightening method, but it
has been pointed out that it takes a lot of time.
Alternative #1 and #2 are methods to reduce thenumber of tightening bolts in the first step byincreasing the torque stepwise for four different bolts

No.38

in Step 1 and Step 2.
Alternative #3 is a simple tightening method similar to
JIS B 22517） where only four bolts are temporarily
tightened and then circumferentially tightened.
The final steps of the four tightening methods
described in ASME PCC-16）are "until the nut no longer
turns," and the number of tightening times describedin Table 2 is the result of the number of times the nut
no longer turns in this test.

Figure3

Distribution of the flange gap

3-3）Tightening method 3 Rounds

4-2）Bolt axial force distribution

In addition to JIS B 2251 and ASME PCC-1 tightening

Figure4 and 5 show the final bolt axial force distribution

methods, a convenient way to make three cycles ofand the variation in axial force, respectively when the

cross tightening in stepwise is also examined.

gasket was No.GF300. Regardless of the tightening
method, variations in axial force are observed due toelastic interaction. In particular, the variation was large
in the 3 Rounds method, and the tightening coefficient Q（=Fmax/Fmin）was 2.62. Regarding the minimum bolt
6Influence of Bolt Tightening Methods on the Sealing Performance of Large Diameter Bolted Pipe Flange Connections

axial force Fmin, the target bolt axial force of 85.6 kN

Q=1.47 in JIS 110%, showing the smallest value. In

could not be achieved with all tightening methods due

addition, the value of Q indicates that the tightening

to the influence of elastic interaction. According toof No.6596V is larger than that of No.GF300.

this, the value of Q in JIS 110%
（Table2）
is 1.31, and thevalue of Q in Alt#3 is 1.33, indicating the smallest4-3）Sealing performancevalue.

Figure8 shows the measurement results of the leakFigures6 and 7 show the final bolt axial force

rate of the pipe flange connection tightened by each

distribution and the results of variation in axial force,

method. Regardless of the tightening method, therespectively when the gasket was No. 6596V. As inamount of leakage was smaller in the case where thethe case of No.GF300, the variation was remarkablegasket was No.GF300 than in the case where theby 3 Rounds method and one of the three bolts had

gasket was No.6596V. The figure also shows thezero axial force. In Figure 7, the value of Q becomes

smallest bolt axial force Fmin of 24 bolts. Comparing

Winter 2020
No.38

Distribution of final axial bolt force（No.GF300）

Figure6

Distribution of final axial bolt force（No.6596V）

Figure7

Variation of final axial bolt forces（No.6596V）

Axial Bolt Force［kN］

Axial Bolt Force［kN］

Figure4

Tightening methods

Tightening methods

Figure57

Variation of final axial bolt forces（No.GF300）

Technical Papers

understood that the leakage amount decreases as theminimum bolt axial force increases. Conversely, thesmaller the minimum bolt axial force, the smaller thegasket contact stress locally and the larger the
leakage amount. In other words, the minimum gasket

Moving Distance［m］

the leak rate by each tightening method, it iscontact stress has a large effect on the leakage. In thecase of a pipe flanged joint with a gasket, if the bolt
axial force is low in some parts, it is considered thatTightening methods

leakage is likely to occur from the gasket contact

Figure9

surface in the vicinity. It has been shown that it is

Wrench’s Moving distanceimportant to increase the minimum bolt axial force asmuch as possible to improve the sealing performance.

4-5）Tightening time
Figure10 shows the tightening time required for eachof the six tightening methods. In this experiment, thegap between the flange faces was measured during

Leak Rate［Pa.m3/s.m］

the tightening, but the results in Figure 10 do notinclude the gap measurement time. JIS B 22517） andtightening bolts, have a longer tightening time, andthe 3 Rounds tightening method with a smaller
number of tightening bolts has the shortest tightening
time. Although a torque wrench was used in thisTightening methods

Winter 2020

ASME PCC-16） Legacy, which has a large number ofstudy, the tightening time may greatly varydepending on tools such as a hydraulic wrench andtorque tensioner and the environment at the site.

Sealing Performance4-4）Moving distance of wrench
Figure9 shows the moving distances of the wrenches
when tightening in six different tightening methods.
The moving distance is calculated not by the straightline distance between the bolt holes but by theTightening Time［min］

Figure8

shortest distance along the circumference. JIS B 2251
and ASME Alt#3 had relatively shortmovingdistances. 3 Rounds method has a long moving
distance in spite of the least number of tightening
bolts. It can be said that the moving distance becomes

Tightening methods

Figure10

Tightening timeshorter in the tightening method in which there aremany circumferential tightening, and it can be said
that the moving distance becomes longer in thetightening method in which there are many crosstightening.
8

No.38

Influence of Bolt Tightening Methods on the Sealing Performance of Large Diameter Bolted Pipe Flange Connections

5. Summary

by 1/η.（JIS B 22517））The basic idea of 110% is totighten 10% larger. However, this is based on the bolt

In this paper, sealing performance, flange gap, bolt

axial force and is not always appropriate, and it hasaxial force, moving distance of torque wrench andbeen proposed to use the assembly efficiency based ontightening time of two gaskets of No.GF300 andtightness parameter9）. It seems that there is room for

No.6596V were used when tightened by seven

improvement to a more efficient tightening method todifferent tightening methods, were measured using a

improve the sealing performance required for thelarge- diameter pipe flange connection, and the following

gasketed flange connection. We hope that thisresults were obtained.

research will help the plant tightening work.

（1）‌No significant difference was found in the flange

We were advised by Mr. Koichi Morimoto of Mitsubishi

gap distribution according to these tightening

Chemical Co., Ltd. about this experiment. We would

methods.

like to express my gratitude by noting.

（2）‌The sealing performance of pipe flange fasteners is
affected by the tightening method and JIS B
22517）110% tightening method has the least leakrate. Then, JIS B 22517）was 100%.

Winter 2020
No.38

7. References

Although it

1）‌A. Muramatsu，“ Seal Training Center （STC）

was observed that the 3 rounds tightening-Interactive Training for Sealing Operation”，

method was simple but the sealing performance

Valqua Technology News Vol.33，（2017）

was inferior.

2）‌H. Lejeunt, Y. Birembaut, Alexander Riedl, Arne（3）‌It was observed that the sealing performance of

Schunemann," Investigation on Different Tightening

pipe flange joints are affected by the minimum

Methods on Several Bolted Flange Types,

bolt axial force and it is important to increase thedimensions and Their Associated Gasket Types",

minimum bolt axial force as much as possible to

PVP2011-57525, Proceeding of ASME PVP 2011

improve the sealing performance.

Conference,（2011）（4）‌As for the tightening method, the moving distance3）‌H. Gong, Russell R. Flocken", Study of Bolt Tighteningof the torque wrench tends to lengthen when the

Methods Using Load Indicating Bolts", PVP2016-

cross tightening is large, and as for the tightening

63723, Proceeding of ASME PVP 2016 Conference,

method with a large number of tightening times,（2016）

the tightening time tends to longer.

4）‌H. Gong, Wesley Pudwill, Elysia J. Sheu," Study of（5）‌JIS B 22517）and ASME PCC-16）Legacy and Alt

Alternative Assembly Patterns Using Finite#1 have relatively small leaks but require a longer

Element Analysis and Lab Tests", PVP2018-84465,

tightening time. The 3 Rounds method has a

Proceeding of ASME PVP 2018 Conference,（2018）

relatively large leakage but the tightening time is5）‌W. Brown," Efficient Assembly of Pressure Vessel

less than half of JIS B 22517）.

Bolted Joints", PVP2004-2635, PVP-Vol.478,
Analysis of Bolted Joints,（2004）

6. Conclusion

6）‌ASME PCC-1," Guidelines for Pressure Boundary
Bolted Flange Joint Assembly",（2013）

The American Society of Mechanical Engineers

7）‌Japanese Industrial Standards. JIS B 2251“ Bolt

（ASME）has introduced a factor called assembly

Tightening Method for Pressure Boundary

efficiency η. η is the ratio of the final axial bolt force toFlanged Joint Assembly”,（2008）.

the target axial bolt force, and the value is less than 1.

8）‌T. Fujihara,“Effects on Sealing Performance of Pipe

In other words, in actual design and construction, theFlange Connections Tightened by Different

target value of the bolt axial force is further increased

Tightening Methods”，Valqua Technology News

9

Technical Papers

Performance of Bolted Gasketed Pipe Flange

Vol.37,（2019）.
9）‌X. Zheng, K. Sato, T. Fujihara, Y. Akamatsu, T.Sawa,"Effect of Tightening Method on the Sealing

Xing Zheng
China Research Institute
Seal Engineering
Development Group

Connections", PVP2019-93497, Proceedings of ASME
PVP 2019 Conference,（2019）

Kouji Satou
Corporate Research andDevelopment Group
Product Development
Division

Takahiro Fujihara
Toshiyuki Sawa
Hiroshima University,
Professor Emeritus

Winter 2020

Corporate Research andDevelopment Group
Product Development
Division

No.38

10

Evaluation of the Compression methods on the
Sealing Performance of Gland Packing
gland packing of different materials. In addition, the

1. Introduction

operation time required for each compression method

The gland packing serves to seal the internal fluid by

was measured and evaluated from the viewpoint oftightening the packing gland with bolts andsealing performance and operating efficiency.

compressing the gland packing. For this reason, it has
been found that the sealing performance greatly
depends on the compression pressure. However, theWinter 2020
No.38

2. Test method

effect of the compression method is unknown. The

2-1）Test equipment and test method

compression method includes batch compression in

Figure1 shows a schematic diagram of the compression

which several rings are compressed at one time andequipment. Using this test apparatus, the sealing

divided compression in which compression is

performance by the compression method in the batch

performed several times for every two or three rings.

compression and the divided compression was

It is thought that the divided compression increases

compared. Furthermore, the sealing performance atthe density of the gland packing and improves thethe time of recompression, which has the same effectsealing performance, but the quantitative effect is not

as retightening after batch compression or divided

known. In addition, batch compression is generallycompression, was also measured. Three types of gland

used because it takes time for divided compression. In

packing were used: carbon fiber gland packing

this study, the effect of the compression method on（No. 6137）, PTFE gland packing（No. 7233）, andthe sealing performance was evaluated along with the

expanded graphite gland packing（No.VF-10T）.

mechanical behavior such as stress relaxation using2-2）Test conditions
Compression
equipment
N2

Compression pressure：19.6MPa
Leak-measurement

Stem

Gland

Fluid：Nitrogen gas
Fluid pressure：1, 5, 10 MPa
Gland packing ring number：6 pcs
2-3）Test method

Gland packing

Four compression methods were used: batchcompression, batch compression +recompression（hereinafter referred to as "batch +recompression"）,divided compression, divided compression+recompression（hereinafter referred to as "divided+recompression"）. After stress relaxation was

Figure111Compression equipment and test equipment

stabilized, sealing tests were conducted.

Technical Papers

Batch compression:①②

batch +recompression > divided +recompression. SinceSix gland packing rings are attached to the test

the leakage decreases with the compression method withequipment.

high residual stress, it can be concluded that there is aAfter compressing the gland packing withcorrelation between residual stress and leakage.

compression equipment at 19.6 MPa for 30
seconds, fix the head position of thecompression equipment.
③

Wait until stress relaxation stabilizes④

Nitrogen gas（1, 5, 10 MPa）was used into the test
equipment for leakage measurement⑤

Exhaust nitrogen gas⑥

Perform recompression（batch + recompression）
under the same conditions as step ②⑦

Carry out steps ③ to ④ .

Figure2

Residual stresses of carbon fiber（No.6137）

Divided compression:①

Two gland packing rings are attached to thetest equipment.
R elease the compression equipment after

Winter 2020②

compressing the gland packing with a compression
equipment at 19.6 MPa for 30 seconds③

① to ② are repeated twice, a total of 6 pieces
are mounted, and the head position of thecompression equipment is fixed④

Wait until stress relaxation stabilizes⑤

Nitrogen gas（1, 5, 10 MPa）was used into the test⑥

Leakage of carbon fiber（No.6137）

No.38

equipment for leakage measurement

3-2）PTFE gland packing（No.7233）

Exhaust nitrogen gas

Figure4 shows the residual stress after stress⑦ Perform recompression（divided + recompression）⑧

Figure3

relaxation of PTFE gland packing（hereinafter, PTFE）

under the same conditions as step ②

and Figure5 shows the sealing test results after stress

Carry out steps ④ to ⑤

relaxation. The residual stresses of batch compression
and divided compression became almost the same, and

3. Test Results and Discussion

batch +recompression and divided +recompression
also became almost the same. However, the difference3-1）Carbon fiber gland packing（No.6137）

was found in each sealing performance.

Figure2 shows residual stresses after stress relaxation ofThis is because, as shown in Figure6, In the case ofcarbon fiber gland packing（hereinafter, carbon fiber）.

one-time compression , the number of times the

The order of the lowest residual stress was as follows:

compression is pressed against the sealing surface isbatch compression < divided compression < batch

small, and the gap between the sealing surface and the+recompression < divided +recompression.

gland packing becomes large, so leakage increases but

Figure3 shows the sealing test results after stressfor divided compression, the gap between the glandrelaxation. The order of large amount of leakage was as

packing and the sealing surface was filled by the threefollows: batch compression > divided compression >times compression, and the leakage was reduced.
12

Evaluation of the Compression methods on the Sealing Performance of Gland Packing

Figure8 shows the sealing test results after stressrelaxation. Carbon fiber and PTFE leaked less in batch+ recompression than divided compression, whereas
expanded graphite leaked less in divided compression
than batch + recompression. In the case of the divided
compression, the compression is released once to insert
the next gland packing. Since the expanded graphite is
obtained by pressing and solidifying the powder, it isdifficult to recover even if the compression is released
Figure4

Residual stress of PTFE（No.7233）

by divided compression, the leakage of divided
compression is less likely to occur because deteriorationof density and conformity of the sealing surface issmaller than batch +recompression.
Since the fibrous carbon fiber and PTFE are easily
restored, it is considered that the density of the glandpacking is reduced and the conformity to the sealing
surface is easily deteriorated, and the effect of the split
compression is considered to be smaller than that ofWinter 2020

the expanded graphite.
Figure5

Leakage of PTFE（No.7233）

No.38

Figure7 Residual stresses of expanded graphite（No. VF-10T）

Figure6 Relationship between compression method and gap3-3）Expanded graphite gland packing（No.VF-10T）
Figure7 shows the residual stresses after stressrelaxation of the expanded graphite gland packing（hereinafter, expanded graphite）. Expanded graphite
originally had small voids and high density, so stressrelaxation was small and the residual stress is as highas 95% or more in all compression methods, thedifference between compression methods was also

Figure8

Leakage of expanded graphite（No. VF-10T）

small. There was almost no difference in the residual

3-4） Effect of compression method for each packing type‌stress between the compression methods, but there

Figure9 shows a graph comparing the effects of thewas a difference in the sealing performance.

compression method for each packing material. The

13

Technical Papers

vertical axis of the graph represents the rate ofis recommended for applications requiring high sealingchange of the leakage of the other compression

performance.

methods when the leakage of the batch compression of
the blue bar is 100%. Divided+recompression was theleast leaking compression method for all types ofpacking.
Comparing batch +recompression and divided+recompression, the difference in carbon-fiber and
PTFE leakage was 10-14% and the difference due tocompression methods was small. On the other hand,the difference in leakage of expanded graphite was
43%, and the difference by the compression method
became large. As described in 3-3）, carbon fiber and
PTFE are fibrous and easily recovered, whereas

Figure10expanded graphite is hard to recover because it is

4. Conclusion

manufactured by solidifying powder. As a result, it isOperationaltime of compression methods

This study was able to evaluate the relationshipconformity to the sealing surface is not easily

between sealing performance and operation time due

deteriorated. Therefore, it is considered that the effectto differences in compression methods. Under theof the divided compression is remarkably obtained inpresent test conditions, in the case of carbon fiber andthe expanded graphite.

PTFE, since there was no significant difference in theleakage of batch + recompression and divided +recompression, it is recommended to perform

Winter 2020

unlikely that the density is reduced and the

additional tightening after batch tightening from theviewpoint of operational efficiency. In the case of
expanded graphite, if the operational efficiency isprioritized, perform retightening after batchtightening, and if prioritizing sealing performance, use
retightening after divided tightening. It has been
Figure9 Differences in leakage amount due to compression methods

observed that the desired effect can be selected byusing an appropriate compression method.

3-5） Operation time for each compression method

It takes a lot of time to attach and detach the gland

Figure 10 shows the operation time for eachpacking and to tighten it in the plant site. We hopecompression method. The time required for thethat this study will help improve the tightening

divided + recompression was 3.6 times that of theefficiency of the gland packing.

batch + recompression. Performing divided +recompression with carbon fiber and PTFE with a 1014% difference in leakage is considered to beinefficient.
Divided + recompression with expanded graphite
showed 43% better sealing performance than batch +recompression. Division + recompression took 3.6
times operation time than batch + recompression, so it

Masato Hamade
Corporate Research andDevelopment Group
Product Development
Division
14

No.38

Comparison of Semi-Metallic Gasket’s
Performance andIntroduction of Kammprofile Gasket Series
1. Introduction

JIS B 2490. The paste（No. 6）was applied to the metal
jacketed gasket based on the general usage.
Sealing performance of the spiral wound gasket wasenergy, semi-metallic gaskets such as Spiral Woundthe best at room temperature. The kammprofile

Gaskets, Metal Jacketed Gaskets, and Kammprofile

gasket and metal jacketed gasket have a large

Gaskets are often used.

amount of leakage at low gasket contact stress（12.5-50

Spiral Wound Gaskets are widely used from piping toMPa）, and when loaded with 50 MPa or more, theequipment, and Metal Jacketed Gaskets are often used inleak amount is less than the measurement sensitivity.

equipment such as heat exchangers because they have a

The sealing performance is higher than the detection

narrow seal width and can make branched gaskets. The

level of the soap bubble test used for the leakKammprofile Gaskets have been widely used overseas,

detection at the plant.

but in recent years, it is becoming popular in Japan

Contact gasket stress［MPa］ Test conditions
Seal test method
No.6596V_t4.5
Sample Dimension
No.6540H_t4.0
Internal pressure
No.N520_t3.0_Gasket Paste
Range of measurement
No.6 applied

because of its excellent performance and due to easy
handling.

：JIS B 2490
：JIS 20K 50A：4.0 MPa (He)
：1.7×10 －5 ～ 1.7×10 －1 Pa･m3/s

No.38

way, but with the aging of equipment and thediversification of attitudes toward maintenancemanagement, they have come to be re-selectedaccording to usage conditions. However, there are few
performance comparison data for these semi-metallic

Leak rate［Pa・m3/s］

Though semi-metallic gaskets have been used in this

Detection level ofsoap bubble test

gaskets. Therefore, this report presents comparativeevaluation data of semi-metallic gaskets which provide
an indicator for users to select gaskets. At the sametime, we will introduce the features of the Kammprofile

Contact gasket stress［MPa］

Winter 2020

In the fields of petroleum refining, petrochemical, andTest step

Figure1

Room Temperature Sealing Performancegasket series which expanded our lineup.

2-2）Compression and recovery characteristics

This study was conducted with Spiral Wound Gasket

Figure2 shows the compression and recovery（No.6596V）
using expanded graphite, Kammprofile Gasket

characteristics. The difference in the amount of gasket（No.6540H）, and Metal Jacketed Gasket（No.N520）.

displacement between the contact gasket stress at 5
MPa and 100 MPa was defined as the amount of

2. Comparative evaluation

compression. The difference in the amount of gasket
displacement between the contact gasket stress at 1002-1）Sealing performance at room temperature

MPa and 12.5 MPa was defined as the amount of

Figure1 shows the sealing performance at room

recovery. Table 1 shows the compression and recovery

temperature. The evaluation was performed based onamounts of gaskets.

15Technical Papers

Table1 shows that the spiral-wound gasket had theheating was less than the measurement detection

largest amount of compression and recovery. For thelevel, but the leak amount increased after the heating.

metal jacketed gasket, the compression amount wasThis is thought to be due to the decrease in thelarge but the recovery amount was small, and for the

resilience of the core material due to repeated thermal

kammprofile gasket, both the compression amount andcycles.

the recovery amount were small. If the flange gap
fluctuation is large due to thermal cycling, a spiralwound gasket with the best compression recovery

No.6596V（Contact stress
70 MPa）

No.6540H（70 MPa）

No.6596V（50 MPa）

No.6540H（100 MPa）

Sample Dimension ：JPI Class300 2B
No.N520（70 MPa）
Heating temperature ：400 ℃（Applied No.6） Heating time
：15 hours
Internal pressure ：4 MPa（N2）Seal test method ：S ubmersion
methodRange of measurement ：0.1～5000 cc/min

characteristics isappropriate.

t4.5

Compression［mm］
Recovery［mm］
Contact gasket stress Contact gasket stress
5 MPa → 100 MPa 100 MPa → 12.5 MPa
0.850
0.198

No.6540H t4.0
No.N520 t3.0
（Applied No.6）
No.6596V_t4.5

0.432

0.060

0.918

0.079

Test conditions
Sample Dimension

No.6540H_t4.0

Reak rate［cc/min］

No.6596V

Compression recovery characteristics

Leak rate［Pa・m3/s］

Table1：JIS 20K 50A

Before Heating

Figure3

1 cycle3 cycle5 cycleThermal Cycle Sealing Performance at 400℃

No.6540H（Contact stress
70 MPa）

No.N520（70 MPa）（Applied No.6）

No.6540H（100 MPa）

Sample Dimension		

：JPI Class300 2B

Heating temperature：500 ℃

Heating time		

：15 hours

Internal pressure		：4 MPa（N2）Seal test method 		

: Submersion method

Range of measurement ：0.1 ～5000 cc/min

No.38

Displacement［mm］

2-3）‌Sealing performance at high-temperaturethermal cycling

For evaluation of sealing performance at hightemperature, heating and cooling are repeated while
the gasket was tightened to the flange and evaluation

Reak rate［cc/min］

Compression Recovery Characteristics
Leak rate［Pa・m3/s］

Figure2

was carried out after cooling.
Figures3 and 4 show the sealing performance with thethermal cycle. The tightening contact gasket stress
was set to 70 MPa for all samples, and therecommended tightening contact gasket stress for

Before Heating

Figure4

1 cycle3 cycleWinter 2020

Contact gasket stress［MPa］

No.N520_t3.0_Gasket Paste
No.6 applied

5 cycleThermal Cycle Sealing Performance at 500℃

each gasket was also used. The heating temperature
was 400℃ and 500℃ .

2-4）Selective use of semi-metallic gaskets

From Figure3 and 4, the spiral wound gasket and theSpiral wound gaskets are the best semi-metallic

kammprofile gasket maintained stable sealing

gaskets in terms of performance. However, it may be

performance. On the other hand, in the case of the

difficult to use the spiral wound gasket, such as ametal jacketed gasket, the leak amount before thelarge diameter which is difficult to handle and a shape16Comparison of Semi-Metallic Gasket’s Performance and Introduction of Kammprofile Gasket Series

witha narrow gasket width. Therefore, when theheating temperature was increased, but the leakage

diameter of the gasket is less than about φ1000 mm

amount of No.6540H increased significantly. This is

and the seal width can be secured, the spiral woundbecause expanded graphite disappears due togasket is appropriatee. On the other hand, when aoxidation.Since the expanded graphite graduallylarge diameter（φ1000 mm or more）and seal widthoxidizes and disappears above 400℃ , long-termcannot be secured, or when working at high places, asealability maintenance is a concern. Figure6 and 7

kammprofile gasket or metal jacketed gasket

show the rate of weight loss over temperature andisappropriate. Also, metal jacketed gaskets have thetime for expanded graphite sheet and VALQUA

advantage that they can be processed into various

HEAT RESIST SHEETTM. Figure7 shows the evaluation

shapes such as ellipses and rectangles and are more

result of up to 240 hours. However, the expanded

economical than kammprofile gaskets.

graphite decreases even at temperatures of about
400℃ to 500℃ , the sealing stability is a concern in the

3. Kammprofile gasket series

long term of 2 to 4 years. The VALQUA HEAT RESISTSHEETTM loses a little weight at the beginning ofWinter 2020

3-1）Features

heating, and most of it remains unchanged in the long

As previously stated, the kammprofile gasket isterm. In addition, even if the heating temperature isbecoming increasingly spread in Japan in recent

raised, the rate of decrease remains unchanged, andyears. In response, we have developed a new profile

the rate of decrease in the long term is also constant,gasket and expanded our product lineup. According toresulting in stable sealing.

the usage conditions, it became possible to select theNo.6540H（Contact stress 100 MPa）

surface layer material to be bonded to the metallic
serrated gasket.

No.HR540H（100 MPa）

Expanded graphite sheet laminated productSample Dimension ：JPI Class300
Heating temperature：600 ℃

Heating time

：15 hours

2B

Internal pressure：0.5 MPa（N2）Seal test method：Submersion method

Range of measurement ：0.1 ～ 5000 cc/min（No.6540H）is a general-purpose product that can behigher which is a temperature range in which
expanded graphite is liable to disappear by oxidation,
the more heat resistant VALQUA HEAT RESISTSHEETTM laminated product （No.HR540H） isappropriate. PTFE sheet laminated product（No.7540H）
is used at lower temperatures than the expanded

Reak rate［cc/min］

used under various conditions. When used at 400℃ or
Leak rate［Pa・m3/s］

No.38

graphite product, but it is appropriatefor lines where
it is difficult to use expanded graphite due to theconcern of contamination.

BeforeHeating

Figure53-2）Characteristic evaluation

1 cycleAfter
retightening

2 cyclesThermal Cycle Sealing Performance at 600℃

Heat resistance is one of a features of No.HR540H.

Large diameters pipe flange connections or equipment

Figure5 shows the thermal cyclic characteristics atmay be subjected to flange rotation, etc., and the gasket

600℃ of a kammprofile gasket with a surface layer a

may have a load greater than the recommended

TM

VALQUA HEAT RESIST SHEET

and an expanded

tightening contact stress. Therefore, there is a concern

graphite sheet.

that the metal part is exposed at the time of tightening

From the results at 600℃ , the leakage amount ofand may damage the flange. Table2 and Figure8 show

No.HR540H did not change significantly even when thethe evaluation results of kammprofile gasket’s surface

17

Technical Papers

material which is cracked by applying excessive
contact gasket stress. In No.HR540H and No.6540H, noNo.HR540H

200 MPa

No.6540H

200 MPa

No.7540H

140 MPa

metal exposure was observed even when a contact
gasket stress of 200 MPa was applied, and there is alittle risk of damaging the flange even if an excessive
contact gasket stress was applied. In No.7540H, metal
exposure was confirmed at a contact gasket stress of
140 MPa. This is probably because the PTFE sheet iseasier to flow than the expanded graphite sheet.
However, the recommended tightening contact gasket
stress of No.7540H is 60 MPa, and even if a contact
gasket stress twice as high as the recommended tightening
contact gasket stress is applied, no metal is exposed
and it is considered that there is no problem in use.

Winter 2020

Weight loss rate［%］VALQUA HEAT RESIST SHEETTM Heating time：72 hours
（In the air）
Expanded graphite sheet

Heating temperature

Figure6

Change in weight loss rate with temperatures
VALQUA HEAT RESIST SHEETTM
Expanded graphite sheet

Heating temperature：550℃
（In the air）

Figure8

Appearance after excessive contact gasket stress

4. Conclusion

Weight loss rate［%］In domestic petroleum refining and petrochemicalplants, more stable sealing products are required dueto the aging of plants and the prolonged periodic
maintenance. We hope the performance comparison ofthese semi-metallic gaskets and the kammprofile
gasket series will be an good option in selecting
gaskets.
Heating time［hour］

Figure7

Change in weight loss rate with times

Table2

Change in weight loss rate with times

Sample Dimension
VALQUA HEATRESISTSHEETTM
Expanded graphite
No.6540H
sheet

No.HR540H

No.7540H

PTFE

sheet

Metal exposure
No metal exposure at
200 MPa
No metal exposure at
200 MPa
metal exposure at
140 MPa

Satomi Takahashi
Corporate Research andDevelopment Group
Product Development
Division
18

No.38

Introduction of High-speed Opening
and Closing Cylinder Valve
1. Introduction２-2）Good operating reliability

Conventionally, ball valves and butterfly valves have

Because of the internal structure is simplified and the

been frequently used as automatic pneumatic valves

number of moving parts is reduced, the occurrence of

which can be opened and closed in a short time andtrouble is extremely low. In addition, since the entire

have low fluid flow resistance, but there have been

valve has a cylindrical shape has sufficient strength todifficulties in "durability and high-speed actuation".

withstand a sudden pressure load due to the water

Though these difficulties rarely become a problem inhammer phenomenon and does not malfunction.

normal conditions, they sometimes become problematic

Winter 2020
No.38

in rolling line’s cooling water switching valves in steel２-3）Compact and easy to handle

mills used in high frequency and high-speed operation.

As the valve incorporates a drive unit and is integrated,

The problem is that the valve seat seal part is in

it is compact, light, and easy to handle. Since the drive

sliding contact, and it is difficult to achieve good

unit does not protrude, the space for piping can besealing for a long time because the valve seat is worn

reduced, and there is no limitation on the mounting

and damaged due to the accumulation of theprocedure. Figure1 shows a sample image of aoperations. In addition, when the opening and closing

cylinder valve cut sample.

operation time is short, the sudden increase inpressure on the primary side of the valve due to thewater hammer phenomenon caused by sudden closing
causes damage to the valve seat seal, valve support
bearing, and operating stem and as a result, the valve
may become inoperable.
In this report, we introduce the High-speed opening
and closing cylinder valve, which was developed, andhas been manufactured and sold about 40 years ago,
has added value to solve these problems, and is still
being selected by our customers.
Figure1

2. Features

Cylinder valve with built-in drive unit

２-4）High-speed operation２-1）long sealing life

The moving parts are lightweight and have a shortSince the valve seat seal is not in sliding contact,

working stroke, enabling high-speed operation andthere is no deterioration in sealing performance due togood operability. Table1 shows a list of operating

friction.

times for standard specifications.。

19

Product Introductions

Table1

Standard operating time of cylinder valve

OPERATION TIME（SEC.）FLUID
PRESSUREOPERATIONNOMINAL SIZE

15A
20A
25A
32A
40A
50A
65A
80A
100A
125A
150A
200A
250A
300A
350A
400A
450A

0.98MPa

USE AIR APPARATUS（MADE BY KONAN ELE.）

1.96MPaSPEED
SOLENOIDCONTROL
SHUT
VALVE
↓
VALVE

OPEN
↓
SHUT

SHUT
↓
OPEN

OPEN
↓
SHUT

OPEN

0.10
0.11
0.14
0.21
0.21
0.33
0.30
0.34
0.44
0.68
0.94
1.7
2.4
2.6
3.1
3.4
4.8

0.10
0.10
0.12
0.19
0.19
0.28
0.26
0.29
0.38
0.59
0.81
1.5
2.0
2.1
2.6
3.1
4.5

0.10
0.13
0.17
0.26
0.26
0.43
0.36
0.42
0.57
0.85
1.2
2.1
3.1
3.5
4.0
3.8
5.3

0.10
0.10
0.12
0.17
0.17
0.26
0.25
0.27
0.35
0.54
0.74
1.3
1.8
1.9
2.4
2.8
4.1

3. Structure and Operation
The main components of the cylinder valve are themain body, the cap, and the piston, and the structure issuch that the seal material for each joint and themovable part seal is used. Figure3 shows the cross-

453S202C
SC6-02-8A
413S302C

sectional diagram of the two-way cylinder valve. Also,a three-way cylinder valve can be made by attaching a
T-shaped part to the primary side（body line flange

413S603C SC6-04-10Aside）of the two-way valve. Figure4 shows the crosssectional diagram of the three-way cylinder valve.
The piston moves to the valve seat side or the non-

413S604C SC6-04-15A

valve seat side by switching the operating air pressure
supplied to the cylinder（body）. When the piston

413S806C SC6-08-20A

moves to the valve seat side, the tip of the piston ispressed against the valve seat packing, sealing thefluid flowing through the main body flow path and the

The effect of internal fluid pressure on valve

inside of the piston, and the valve becomes“closed”.

operation is minimized, so the effective cylinder area

Next, when the operating air pressure is switched andis small. The amount of compressed air required forthe piston moves to the opposite side of the valve seat,

operation is less than the amount required to operate

the space between the tip of the piston and thea ball valve of the same size.

packing of the valve seat is opened as a flow path, andthe fluid flows through the main body flow path andWinter 2020

２-5）Low air consumption２-6）Low fluid flow resistanceIn a valve where the valve seat does not make sliding

No.38

contact（eg a globe valve）, the flow resistance is large
because the flow direction of the fluid changes several
times, but the flow direction of the cylinder valve issmall. In addition, since the flow path is streamlined,
the flow resistance is small and can be used for
relatively large flow applications. Figure2 shows therelationship between the Cv value, differential
pressure and flow rate of the two-way valve.
Figure3

Cross-section diagram of 2-way cylinder valve

Figure4

Cross-section diagram of 3-way cylinder valve

flow rate

Figure2 R elationship between Cv value, differential pressure,and flow rate

20

Introduction of High-speed Opening and Closing Cylinder Valvethe cap flow path through the piston inner part andspeed opening and closing, automatic valve

the valves becomes“Open”.

5-1-2）PSA type nitrogen gas generator

The opening and closing state of the valve can be

Gas switching valve for PSA type large mounted

easily checked visually with an opening and closing

nitrogen gas generator.

indicator attached to the piston. In addition, by

Customer needs: sealing life, sealability, high-speed

attaching an operation bar to the opening and closing

opening and closing, automatic ON-OFF valve

instruction rod, it is possible to detect the opening andclosing state using limit switches and proximity5-2）Examples of new applications

switches, and to attach a positioner and control valves.

Recent application examples are introduced below.
5-2-1）Theme Park fountain equipment

4. Standard Specifications

Cylinder valves are used as ON-OFF and control

The standard specifications of the cylinder valve arevalves for fountain effects. The fountain flow rate

as follows.

control with high-speed opening and closing■ Wetted metal material … SCS13, SUS304

contributes to a more expressive show than ever

■ Packing material…… ‌NBR, AU（Select others

before.

depending on the fluid）■ Connection… ……… ‌JIS 10k, 20k flanges（CLASS

Winter 2020
No.38

Used for shows including fountains in theme parks.

150 is also acceptable）

Customer needs : operation reliability, high-speed
opening and closing, automatic ON-OFF valve, control
valve■ Size… ……………… Nominal size 15 A〜450 A

5-2-2）Factory Wastewater Equipment Filter■ Sealing life… ……… 500,000 cycles

Factory wastewater is discharged outside the factory■ Max. operating pressure …… According to Table2

when it meets the standards through a filter. The■ Operation Air Pressure …… 0.4〜0.7MPa

wastewater dust adheres to the filter and filtering■ ‌Operating temperature range

ability may deteriorate if it is used continuously.

…… Depends on packing material（Consultation required）

Therefore, dust is removed by air blow, but if the ON-

Table2OFF valve is used frequently, air leaks inside and theMaximum operating pressure of cylinder valveline must be stopped to perform maintenance.

NOMINAL
PRESSURE

MAX.ALLOWABLE
WORKING PRESSURE

2 WAY
VALVE

10K

1.37MPa

20K

3.33MPa

applications, but the sealing life is short because the

3 WAY
VALVE

10K

0.98MPa

valve seat is sliding contacts. The adoption of a

20K

2.45MPa

cylinder valve can contribute to improving theNote : In case of 20k, 15A to 25A, both 2-way valve and 3-way valve
are 1.97MPa.

5. Applications５-1）Main application
The steelworks and PSA type nitrogen gas generator,

ON-OFF ball valves are usually used in the above

operation rate of wastewater facilities and reducing
maintenance man-hours.
Customer needs : sealing life, automatic ON-OFF valve

6. Conclusion

which were the development purposes, are the main

In this report, we introduced the High-speed opening

applications.

and closing cylinder valve, which solves the

5-1-1）Steelworks（including non-ferrous metals）

customer's difficulties / problems（= challenges）withThick plate and hot rolling line product, cooling rollour reliable seal valve technology solution（= provides

switching valve.

value）.We believe that our customers continue to use

Customer needs: sealing life, operation reliability, high-our products because our products maintain high21

Product Introductions

quality. It is a realization of the fact that our name
"Valqua" comes from "Value & Quality". We willcontinue to explore the potential needs of customers
and provide solutions to build a win-win relationshipwith customers.

7. References1）‌Japan Valve Manufacturers’Association: New
Edition Valve Handbook, 368-370（2011）2）‌Masahiro Kitazawa: Valve Technical Report No. 52,
80-81（2004）

Satoru Murayama
H&S Sales Group
Technical Solutions Division

Winter 2020
No.38

22

Development of Spray BallTM
for Tank Cleaning
1. Introduction
In recent years, CIP（Cleaning In Place）with little orno involvement of workers has become the mainstream
for assembling and removing of industrial tanks andpipes, etc.
This report focuses on cleaning nozzles for cleaning intanks in various industries and introduces the Spray
BallTM（fixed type）and Rotary Spray BallTM of our

Winter 2020
No.38

products and new Rotary Spray BallTM of our developed
products.
Cleaning validations are being implemented for facility
equipment in critical processes in the pharmaceuticalindustry. Our Spray BallTM has also been adopted as

Figure1

Image of Spray BallTM（fixed type）

tanks in all industries, such as medical, chemical, andan important part of cleaning equipment, contributing

food products. Since the wetted part is PTFE having

to the risk management of our customers.

heat and chemical resistance characteristics, makes it
possible to permanently install the product inside a

2. What is cleaning?

tank. In addition, since the spraying position isdesigned according to the customer's tank nozzle

In this report, we define cleaning as removing the dirt

orientation, efficient cleaning is possible in a short time（solid substance adhering to the surface）to the extent

and the consumption of cleaning liquid can bethat there is no problem for the post-process treatment

suppressed.

and processing.

The holes are efficiently arranged by high-precision

In a broad sense, the cleaning also includes removing

machining, and pressure is applied from a small hole toimpurities in the gas or liquid, but it is excluded here.

inject. If the fluid is flammable, conductive PTFE is

The cleanliness of cleaning varies by purpose and use

recommended as the material. This is because staticfrom a level of 100% removal of deposits to a level ofelectricity accumulates during injection, which might

acceptability when it is apparently reduced, and there

cause firing.

is a wide range of demands from each industry.

3. Spray BallTM（fixed type）
Fixed type Spray BallTM is used for cleaning tanks
such as reaction tanks, stirring tanks, and storage
23

Table1

The number of Spray BallTM per tank volume TankvolumeThe number of Spray BallTM
Type～ 600ℓ50

2

1

1 ～ 5㎥

80

2

1

6 ～ 10㎥

100

2

1

Vertical reaction tank Vertical storage tank

Note: The number of units used in the above table is an example.

Product Introductions

Table1 shows the approximate required number ofSpray BallTM.

4. Rotary Spray BallTM

If there are stirring shafts, baffles, etc. in the tank, it isrecommended to increase the number of Spray BallTM
to clean the backside of the shaft.
The structure consists of ① upper ball ② lower ball
③ two-stage flanges as shown in Figure1 & 2. A twostage flange is used to prevent misalignment so thatthe jet can be precisely sprayed to the intended
cleaning point.

Figure3

Image of Rotary Spray BallTM

Rotary Spray Ball TM is similar in application andmaterial properties to fixed Spray BallTM but has theStandard design of Spray BallTM（fixed type）

following features.
● ‌Rotary Spray BallTM is composed ofTable2 shows the standard dimensions.
Table2

Cleaning
Flangewater
vlume combination（L/min）

φC

SB-50

15 ～ 40

25A×50A

SB-80

30 ～ 70

SB-100L（maximum）
PTFE

Conductive
PTFE

46

400

300

25A×80A

72

600

370

70 ～ 100 40A×100A

97

500

370

When attaching the Spray Ball

TM②

shown in Figures4. The upper and lower ballsStandard dimensionsType① bodyupper ball ③ lower ball ④ fixed ring ⑤ collar as

to a T-tube, etc.,

rotate reversely. Since the cleaning water itself

Winter 2020

Figure2

controls the rotation, there are no parts for rotation
inside. Because of the simple structure, we caneasily maintain this.
● ‌Even at low pressure, we can clean efficiently
because the spraying pattern makes a straight bar
flow.

attach a joint or steady rest. This is to prevent the● ‌The spraying pattern（angle）and flow rate（holewarpage due to the concentration of holes at certain

diameter/number of holes） can be changed

locations and the application of spraying pressure.

depending on the customer specifications.

For the flange combination, besides Table2, the size
can be specified. The material of the flange is SUS304
as standard, but other materials such as SS400 can
also be specified.

Figure4Standard design of Rotary Spray BallTM

The mounting method is to insert the collar ⑤ between
the nozzle of the tank and the nozzle on the piping
side. This is because the Rotary Spray BallTM needs
24

No.38

Development of Spray BallTM for Tank Cleaning

not to spray at the target point, unlike fixed typeTMthe inside of each nozzle, not limited to the particular

Spray Ball .

industry.

Table3 shows the standard dimensions.

In the background, small parts such as inside theTable3

nozzles that cannot be cleaned with Spray BallTM haveStandard dimensions

Type

Cleaning
water
vlume
（L/min）

φA

φB

C

Taper
screw

SB-50R

25

100

42

57

1/2”

the tank due to human intervention, causing serious

SB-80R

90

130

64

86

3/4”

damage to the post-process. This is so-called

SB-100R

140

155

88

118

1”

contamination problem.

been cleaned manually by workers using brushes orcloths. As a result, cloth fibers and dust remained in

Therefore, each industry has proposed CIP that

5. Selection of fixed type or rotary typeTM

So far, we have described Spray Ball （fixed type）
TM

eliminating contamination. Another advantage of CIP
is that a certain cleaning effect can be expected soand Rotary Spray Ball , but we have received a lot ofthat the product quality can be stabilized andfeedback about which one should actually be installed,

improved. Because of these factors, CIP became theso we compare the features of each one in a Table4.

mainstream, and cleaning nozzles attracted attention.

Table4Comparing fixed type and rotary type Spray BallTM

Type

Cleaning
water
vlume

Cleaningtime

Spraying
target

Maintenance

Cost

Fixed

〇

〇

〇

△

〇

Rotary

△

△

△

〇

〇

6-2）SolutionsFirst, the cleaning inside each nozzle was examinedusing a fixed type Spray BallTM. When cleaning withthis product, it is possible to clean by increasing theRegarding the amount of cleaning water, cleaning

length of the pipes as shown in Figure5 and spraying

time, and point cleaning, since the fixed type targets

them into the nozzles from the downward direction.

the point for cleaning, it is possible to perform more

However, because the maximum elevation angle isefficient cleaning than scattering the cleaning liquid55°, as shown in Figure2, the area above the fixed

like a rotary type, to suppress the amount of cleaning

type Spray Ball TM cannot be cleaned. In addition,water and cleaning time.

designing the spraying point for each customer's tankOn the other hand, the rotary type is suitable for thenozzle orientation is a laborious work.

rinse in the tank, and it is easy to disassemble and

Next, Rotary Spray BallTM is examined. When cleaning

maintain because of the simple structure. In addition,with this product, it is impossible to wash the inside ofsince the hole diameter is large there is no concern

the nozzle because the maximum elevation angle isabout clogging.

50°as shown in Figure4 and only specific spray axes
pass through.

6. Cleaning challenges

diﬃcult area to clean

6-1）Background
The issue of tank cleaning is cleaning inside eachnozzle.
Conventionally, if head of tank, manholes（hand holes）,

adjust length

Winter 2020
No.38

requires no human intervention with the goal ofand lighting hole（through-lamp openings）in the tankwere able to be cleaned, the cleaning inspection would
have passed. But in recent years, it would have been
judged to be unacceptable if it could not be cleaned to25

Figure5

Washing image of each nozzles

Product Introductions

7. ‌New developed productRotary Spray BallTM

７-2）Hole Pattern type

Straight bar
flow
Liquid film
formation range

As described above, it takes time to design the Spray
BallTM（fixed type）and the inside of the nozzle cannot
be cleaned with the conventional Rotary Spray BallTM.
So we have newly developed a "Slit type" and a "HolePattern type" to meet customer requirements. Next,

Figure8

Cleaning image of Hole Pattern typethe features of each developed product are explained.
The structure and material of the Hole Pattern type
Hole Pattern type

are the same as the standard products, upper andlower balls rotate reversely. It can clean directly

Slit typeabove and below the nozzle tending to be unavailable
for cleaning owing to the straight bar flow. And it canalso clean the manhole, lighting hole, and each nozzle
by small holes vertically arranged in two rows. This
hole reaches the cleaning point while keeping waterpressure, so it exhibits high cleaning power like fixed

Figure6

New developed Spray BallTM

7-1）Slit typemade close by our unique design and processing,which makes it possible to enter each nozzle.
In addition, the efficient cleaning is possible, because
the rotation speed is also low compared with the Slit

Straight bar
flow
Wide area
injection range
Liquid film
formation range

Figure7

Cleaning image of Slit type

Winter 2020

type Spray BallTM. The distance between the holes istype（Figure8）.
7-3）‌Comparison of cleaning rate between standard
Rotary Spray BallTM and newly developed Products
Figure9 shows the comparing the result of cleaning
rate between the newly developed product as "Slittype" and "Hole Pattern type" and conventional Rotary

The structure and material of the Slit type are theSpray BallTM.

same as the standard products. The upper and lower

As observed from this result, the developed products

balls rotate in the reverse direction and efficient

as Slit type and Hole Pattern type are superior to thecleaning is possible. Clean directly above and below

standard product in cleaning in the tank and in thethe area where cleaning is impossible, using a straightnozzle. The Slit type can clean a wider area in a short

bar flow, and clean manholes, lighting ports andtime and the Hole Pattern type reaches the cleaning

nozzles with a wide area jet（slit）.（Figure7）

point while keeping strong pressure, so it is especially

The spraying pressure is slightly weaker than the

superior for cleaning in the nozzle.

hole shape due to the widened slit opening, but theThis cleaning evaluation test is the result described inspray is wider, so it is better at cleaning a wider area

the following section 8 "cleaning evaluation test"

than the hole.

devised by our company. The value in the graph islower because the material having high adhesion anddirty is used to carried out the evaluation test under
26

No.38

Development of Spray BallTM for Tank Cleaning

The cleaning evaluation test method and inspection

severe conditions.

timing are specified in the operation manual of eachcompany, and no particular standards are set in eachindustry.
Our customer may performt the cleaning evaluation
test when delivering our Spray BallTM products. The
purpose is to attach Spray BallTM to the customer'stank and check if cleaning at the level requested byStandard

Hole pattern type

Slit type

Cleaning rate of the tank inside

the customer is possible. In this case, visual inspectionis the mainstream. The method is to spray riboflavinor food coloring（viscosity is about 100cp）, whichlooks like dirt was sprayed thoroughly into the tankand then operate the Spray BallTM for about 1 to 2
minutes（depending on the customer）. After that,visually check that the dirt has been removed. In thecase of riboflavin, it is easy to find dirt because it isStandard

Hole pattern type

Slit type

Cleaning rate of the nozzle inside

Winter 2020
No.38

Figure9

Cleaning rate of the tank and nozzle insidereflected by illuminating the black light, but careshould be taken in handling because it has theproperty of being vulnerable to light. Food coloring isoften used because they are available and handy. In

8. Cleaning evaluation test

the case of visual inspection, as shown in Table5, there
is an advantage that it can be easily implemented and

Typical cleaning evaluation methods include visualan analyzer is not required, but there is a disadvantage

inspection, solvent extraction using water, andthat the determination level is affected by the

sampling from the surface. When determining theknowledge and experience of the assessor. Therefore,cleaning evaluation method, it is necessary to firstin order to eliminate such differences, a new method

consider the general dirt related to the target

was devised for simply quantifying the cleaning

equipment and select an appropriate cleaningevaluation test results. The advantage of thisevaluation method.

evaluation method is that a cleaning evaluation test

Table5 summarizes typical cleaning evaluation

can be easily performed at a low cost because special

methods and their advantages and disadvantages.

materials and analytical equipment are not required,

Table5Comparison of cleaning evaluation methods

Evaluation
methodAdvantage

Disadvantage

Visualinspection

・Easily implementable・‌Surface dirt can bedetected
・No need for analyzer・‌Subjective・‌Cannot detect the entire
equipment・‌Low concentration
substances cannot be
detected

・Easily implementable・‌Can detect detergents
residue
Rinsing water and other water-soluble ・‌Adhesive
cannot be detected
sampling
substances・‌High
precision
analysis
inspection ・‌Can be used for daily
monitoring of thecleaning cycle
Swabinspection

27・‌Depending on inspector
may vary・‌Can be detect attached ・‌results
It is necessary to enter
substancesor disassemble theequipment

and the result can be obtained immediately. Also,
Since it is possible to quantify the value different fromvisual inspection, there is no concern that the
judgment level is influenced by the judgment person.
The challenge is that it is difficult to test the entire
equipment and it is necessary to enter into theequipment.
Now, we are trying to improve this new method forpractical application.

Product Introductions

9. Conclusion

In addition, developing from conventional technology,
we have successfully quantified the cleaningThis report introduces the cleaning nozzle in theevaluation test. Starting with this research, we would

cleaning tank and a new cleaning evaluation test. So

like to try to further improve the cleaning rate andfar, we had only two types of cleaning nozzle, fixed

devise new cleaning methods and strive to develop

and rotary type, so it was difficult to respond to aservices adapted to the times and the environment.

wide range of customer needs.

We will continue to pursue true customer needs and

The development of new cleaning nozzle "Slit type"make efforts to provide new products and services.

and "Hole Pattern type" has made it possible toprovide various spraying patterns. We hope that ourcustomers will be able to select a cleaning nozzle
suitable for each application in the future.

10. References
1）Valqua Valflon Lining Catalog

Mayumi Motoyoshi
Winter 2020

High Performance plastics
Group
Product Division
Technical Support Section

No.38

28

Recent Technology News Back Issues
No.37 Summer 2019
● Greetings

Mutsuo Aoki

Director, Managing Executive Officer CTO & CQO● Customer Solutions（Contribution）
Proposal of New Anti-Corrosion Technology
Tokyo Densetsu Service Co.,Ltd

Misu Tatsuo● Customer Solutions
Introduction to Basic Training of Bolted Flange Connections Assembly with Gaskets
Based on ASME PCC-1

Sales Group

HajimeTechnical Solution Division

Sales Group

NonogakiTakahiro Yamamoto

H&S Business● Technical Papers
Effect of Tightening Methods on Sealing Performance
Corporate Research and Development Group

China Research Institute

Takahiro Fujihara

Product Development Division

Xing Zheng

Team of Seal Engineering & Development

Riichi Morimoto

Mitsubishi Chemical Corporation Okayama Plant

Guidelines for Selection of O-rings Made of Elastomers, and Solutions for Selection Problems
Sales Group

Masatsugu Hoshina

Technical Solution Division● Product Introductions

Winter 2020

Introduction of TOUGHROBER™: Portable Gap and Level-difference Measuring Instrument

Corporate Research and Development GroupP&I Service

Development Division

Manabu Motoori

New Lineup of High Temperature Gaskets Spiral Wound Gaskets No.H590 Series
Kammprofile Gasket No.HR540H
Corporate Research and Development Group

Satomi Takahashi

Product Development Division

No.38
No.36 Winter 2019
● GreetingsPresident & CEO

Toshikazu Takisawa● Introduction to Valqua Technology News No. 36 Winter 2019
Senior Executive Officer Director of Corporate Research and Development Group

Mutsuo Aoki

● Customer Solutions（Joint Authorship）
Introduction of a System for Detecting Abnormal Vibration in Shipboard Equipment～ The Potential of Abnormal Vibration Detection Systems for Preventive Maintenance ～Makoto Haneda

MOL Techno-Trade，Ltd.
Corporate Research and Development Group
Corporate Research and Development Group
Corporate Research and Development Group

Product Development Division Ⅰ

Product Development Division Ⅰ

Advanced Technology Reseach Division

Hisataka Sato

Tetsuya Komeda
Yasushi Aburatani● Customer Solutions（Contribution）
Practical training Equipment for Flange Tightening Force Fluctuation due to Temperature Difference
SHOWA YOKKAICHI SEKIYU CO.,LTD

29

KenichiTakamura

● Technical Papers
Evaluations of Mechanical Properties and Sealing Performance of 24”Pipe Flange
Connections with No.GF300 Gasket
Corporate Research and Development Group
China Research InstituteProduct Development Division Ⅰ

Team of Seal Engineering & Development

Professor Emeritus at the University of Hiroshima

Koji Sato

Xing Zheng

Toshiyuki Sawa

Lining Tank (Application)
Takeshi Yokoyama

Assistant To High Performance Plastics Product Manager● Product Introductions
Long-Lifetime FEPM TOUGHUOROTM
Corporate Research and Development Group

Product Development Division Ⅰ

Hirohumi

Zushi

RyosukeNishi

Low Torque & Long-Lifetime Swivel Joint LFR JOINT

TM

Corporate Research and Development Group

Product Development Division Ⅰ

No.35 Summer 2018
● Greetings

Senior Executive Officer Director of Corporate Research and Development Group

Mutsuo Aoki	Seal Training for Maritime Technique Training in Compliance with an
International Convention （STCW Convention）
H&S BUSINESS GROUP

Takahiro Yamamoto

Winter 2020

● Customer Solutions● Customer Solutions（Contribution）
	Cleaning Plant Facilities Using a Low-Pressure Composite Water Flow Cleaner（Cavitation Cleaning）
Blue Engineering, LTD.

Masaru Kitagawa● Technical Papers
Design Guidelines and Troubles for DYNAMICBELLOWSTM and Countermeasures
Sales Group

Technical Solution Division

Masafumi Ina

Lining Tank（Basics）
 Assistant To High Performance Plastics Product Manager Tomoyuki Kikukawa
Corporate Research and Development Group Product Development Division Ⅱ

Atsuyoshi Iwata● Product Introductions
Substitute Sealants for Refractory Ceramic Fiber
Corporate Research and Development Group Product Development Division Ⅰ

Masato Hamade

Sheet Gaskets for High-Temperature Use VALQUA HEAT RESIST SHEET™ No.HRS
Corporate Research and Development Group Product Development Division Ⅰ

Satomi Takahashi● Recent Technology News Back Issues● From Nippon Valqua Industries, Ltd. to“VALQUA, LTD.”

30

No.38

Aim for earth and people friendly production

Sheet Gasket
UNIVERSALHYPER ™（UF300）
This is a sheet gasket that enables gasket
integration in chemical lines.
In addition to high temperature and long-term
stability, chemical resistance has been improved,
greatly expanding the range of applicable ﬂuids.
It can be used for both strong acid and strong
alkali lines.

BLACKHYPER ™（ＧＦ300）
It is a best-selling seat gasket with a high reputation for reliability
and high cost performance, backed up by proven market
experience.
■UF300, GF300● Allowable temperature ranges : −200 to 300°
C
● Maximum pressure : 3.5MPa※Please refer to the product catalog and technical data.

ThinkPark Tower 24F
2-1-1 Osaki, Shinagawa-ku, Tokyo 141-6024, Japan
Contact : VALQUA, LTD. http://www.valqua.com
TEL：(81)3-5434-7376
FAX：(81)3-5436-0562

VALQUA's Sales Network■JAPANVALQUA, LTD.
【Main Number】【Sales Group】

TEL : (81)3‑5434‑7370
TEL : (81)3‑5434‑7380

FAX : (81)3‑5436‑0560
FAX : (81)3‑5436‑0571

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TEL : (81)436‑20‑8511

FAX : (81)436‑20‑8515

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FAX : (81)3‑5435‑0264■CHINA

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TEL : (86)21‑5308‑2468 FAX : (86)21‑5308‑2478
SHANGHAI VALQUA FLUOROCARBON PRODUCTS CO., LTD.
【Head Oﬃce】
TEL : (86)21‑5774‑1130 FAX : (86)21‑5774‑1244【Jingansi Oﬃce】 TEL : (86)21‑3253‑5588 FAX : (86)21‑3253‑5568■KOREA

VALQUA KOREA CO., LTD.
【Head Oﬃce】
TEL : (82)2‑786‑6718【Ulsan Oﬃce】
TEL : (82)52‑227‑6717

FAX : (82)2‑786‑6719
FAX : (82)52‑227‑6719■TAIWANTAIWAN VALQUA ENGINEERING INTERNATIONAL, LTD.
【Head Oﬃce】
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TEL : (65)6352‑2650
FAX : (65)6352‑2653

No.38 Winter 2019

ThinkPark Tower 24F
2-1-1 Osaki, Shinagawa-ku, Tokyo 141-6024, Japan■THAILANDVALQUA INDUSTRIES(THAILAND), LTD.
【Head Oﬃce】
TEL : (66)2‑324‑0400
FAX : (66)2‑324‑0787【Rayong Branch】 TEL : (66)38‑026‑136
FAX : (66)38‑026‑137■USA

VALQUA AMERICA, INC.
TEL : (1)408‑962‑5030

FAX : (1)408‑962‑5031

VALQUA NGC, INC.
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FAX : (1)713‑691‑4407■VIETNAM

VALQUA VIETNAM CO., LTD.
【Head Oﬃce】
TEL : (84)220‑357‑0078 FAX : (84)220‑357‑0079【Hanoi Branch】 TEL : (84)24‑3222‑2213 FAX : (84)24‑3222‑2216*The VALQUA registered trademark stands for VALUE and QUALITY.
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