U.S. Environmental Protection Agency Disclaimer

The following document, “Valve Packing Specification Template,” was provided to EPA by an industry

representative as an example of one company's procedure for testing and selecting valve packing

technology.  The placement of this document in the docket for this rulemaking does not constitute

endorsement or recommendation. Use of this procedure to test and select valve packing technology

does not guarantee automatic approval of the technology selected. In addition, mention of trade names

or commercial products is not intended to constitute endorsement or recommendation for use.
El Segundo/Richmond/Pascagoula Refinery ES/M

Valve Packing        

Specification Template 

Includes Packing Specification and Installation Guide 

5/1/2011

 

Disclaimer

This is a sample specification.    Any adaptation or

adoption of these suggested procedures or

practices are the responsibility of the end‐user.  Any

use of these materials should be in full compliance

with your company and/or industry safety practices.

Purpose

The goal of this standard is to require the use of the most

technically advanced packing gland products in order to limit

fugitive emissions to the lowest possible level, and make

sure that these products are installed correctly.  Not only will

this benefit the environment, but it will significantly reduce

compliance driven repair costs.   
Table of Contents 

1.0 SCOPE ............................................................................................................................... 1

2.0 LEGAL REQUIREMENTS............................................................................................... 1

2.1 General ................................................................................................................... 1

3.0 RESPONSIBILITIES ........................................................................................................ 1

3.1 Equipment Reliability Manager (ERM) or Designated Representative ................ 1

3.2 Project Engineer ..................................................................................................... 2

3.3 Field Maintenance Supervisor, Machine Shop Supervisor, and Boiler Shop 

Supervisor .............................................................................................................. 2

3.4 Operator, Impact S/D Operator, and OMC ............................................................ 2

4.0 SELECTION OF PACKING ............................................................................................. 2

4.1 New Plants and New Equipment ........................................................................... 3

4.2 Existing Installations .............................................................................................. 4

5.0 REPLACEMENT OF PACKING IN VALVES................................................................ 5

5.1 Procedure ............................................................................................................... 5

60 STOPPING VALVE PACKING LEAKS ON LIVE EQUIPMENT ................................ 6

7.0 ATTACHMENTS .............................................................................................................. 6

Appendix I Packing Selection for Valves 

Appendix II Procedure for Installing Packing in Valves 

Appendix III Valve Tag 

Appendix IV Valve Test Procedure 
VALVE PACKING SPECIFICATION TEMPLATE 

1 

1.0 SCOPE 

This Instruction describes the methods of proper selection, installation, and use of 

packing used in pumps, turbines, compressors, reboiler packing glands and valves in 

volatile organic compound (VOC). This Instruction recognizes that most pump and 

rotating equipment have been converted to mechanical seals. (Some water pumps still 

use packing.) This Instruction is also recommended for all services to minimize leakages 

to the environment. 

If a packing application is not specified below, contact the equipment reliability manager 

or designated representative, or appropriate supervisor for guidance. Make sure the 

correct packing and method is used in each application to ensure compliance with 

environmental laws, and to provide reliable, leak free operation of equipment. 

In case of conflict between this Instruction and Corporate Standard Specifications and 

Drawings, this Instruction shall supersede. 

2.0 LEGAL REQUIREMENTS 

2.1 General 

EPA (Environmental Protection Agency) New Source Review Consent Decree 

limits the amount of VOCs (Volatile Organic Compound) that are allowed to leak 

from any equipment with connections that can include gaskets and/or packing. 

When a leak is detected, NSRCD specifies the amount of time that is allowed to 

stop the leak. Check with your local environmental representative for additional 

details. 

3.0 RESPONSIBILITIES 

3.1 Equipment Reliability Manager (ERM) or Designated Representative 

1) Keeps this Instruction, including the packing selection charts, up-to-date. 

2) Commissions special investigations and corrects problems with packing 

failures. 

3) Recommends alternative packing when the specified packing is 

unavailable or unsatisfactory. 

4) New packing is required to be tested by independent outside labs before 

the packing can be considered for use in the refinery. The ERM shall 

indicate which tests must be administered and will set the requirements for 

acceptability of the new packing. These tests must be standardized and 

allow for a comparison between competing products. Refer to the “Valve 

& Packing Testing Procedure” in Appendix V. (Tests are currently being 

conducted at Yarmouth Research in Maine.) The ERM shall prepare the 
VALVE PACKING SPECIFICATION TEMPLATE 

2 

appropriate engineering, MOC, purchasing specifications and the 

appropriate training for handling and installation of the new packing. 

5) Works with IMI Reliability Lead to specify packing materials to meet IMI 

Machinery needs, and I&E Reliability Lead to specify packing materials 

to meet I&E needs, including control valve packing. 

3.2 Project Engineer 

1) Follows this standard’s requirements for new and rebuilt valves for both 

maintenance and capital projects. Informs ERM or their designated 

representative when problems are encountered in the field or to seek 

guidance on special applications that fall outside this Instruction. 

3.3 Field Maintenance Supervisor, Machine Shop Supervisor, and Boiler Shop 

Supervisor 

1) Confirms that the mechanics are properly instructed and that the 

provisions of this Instruction are followed. Ensures that the ERM or 

designated representative reviews any exceptions. 

2) Selects packing in accordance with Appendix I of this Instruction. 

Verifies that the packing selected is compatible with operating conditions. 

3) Requests the ERM sponsor special evaluations on new or failed packing 

materials. 

4) Updates equipment records (i.e. material changes, valve dimensions, 

packing dimensions and configurations) and proceeds with MOC protocol 

(if needed). 

3.4 Operator, Impact S/D Operator, and OMC 

1) Supplies the service conditions for the packing, including temperature and 

pressure and other pertinent information. 

2) Evaluates the performance of the packing and presents data to ERM. 

Whenever inadequate performance is encountered with packing in existing 

equipment or during early operations of new equipment, Operations will 

inform the ERM of the problem. 

4.0 SELECTION OF PACKING 

The proper packing selection is dependent upon the operating conditions of the 

equipment and should comply with the table in Appendix I. Important parameters to 

consider are stuffing box area, diameter of stem, cross-section of packing, temperature, 

pressure, type of equipment, equipment materials, packing materials, number of packing 
VALVE PACKING SPECIFICATION TEMPLATE 

3 

rings, and type of service. 

4.1 New Plants and New Equipment 

1) The project engineer shall prepare the specification for the equipment and 

select packing dependent upon the operating conditions of the equipment 

in accordance with Appendix I. If unusual conditions arise, consult the 

ERM. In extremely difficult or hazardous cases, the project engineer 

should consult with the packing manufacturer to determine the proper 

packing and either the Company or the packing manufacturer should make 

preliminary tests. (See Section 3.1, item 4.) 

2) New valves with Original Equipment Manufacturer (OEM) packing must 

be listed in the approved valve manufacturers list (AVML) and designated 

“VOC” approved before the valve enters VOC service or they must be 

packed per Appendix I. New valves not listed in the AVML must be 

tested per the testing procedure in Appendix IV. Testing results must be 

submitted to the ETC Piping & Valve Team for approval and acceptance 

before the valve can be added to the AVML as “VOC” approved. 

3) All control valves must have low emissions packing, equal to or better 

than Fisher’s Enviroseal packing. The ERM or designated representative 

must approve any control valve packing other than Enviroseal packing 

before valve enters service. 

4) Clippertech (make by JM Clipper) or Rock Hard (make by Garlock) can 

be used when packing extrusion is a problem or to take up volume (such 

as the stuffing box is too deep) so the number of “sealing rings” is limited 

to five. Note: Pressure seal valves may have more than five rings of 

packing which will require repacking with five rings of packing and the 

remaining space filled with Clippertech or Rock Hard as shown in 

Appendix II, Figure 1. 

5) All new valves must have the packing glands checked for tightness after 

installation and retightened three days after they are placed in service. 

Tags indicating that the valve must be retightened three days after being 

put into service must be affixed to each new valve. The orange tags are 

not to be taken off until the valve has been retightened and approved by 

the responsible maintenance supervisor. An example of an orange tag is 

found in Appendix III. Tags on new valves are provided and attached by 

the valve supplier. Tags on reconditioned valves will be provided and 

attached by the valve service company. 

NOTES:

Some valve manufacturers purposely back off on the packing gland nuts 

for shipping to protect the packing rings from possible extrusion which is 
VALVE PACKING SPECIFICATION TEMPLATE 

4 

why all packing gland nuts must be checked for tightness right after the 

valve is installed. 

Waiting “three days” before doing a retightening of the packing glad is a 

guide that provides a specific time table for those that find it useful. The 

objective is to make sure the packing gland has fully reached operating 

temperature before the gland is retightened. It generally takes about 

24 hours before the packing has fully relaxed in valves that have been left 

at a steady state condition and not operated. Thermal-cycles and 

mechanical operation of valves can also induce relaxation before the 

packing has been retightened. After the retightening, provided it has been 

done properly and at the correct time, the packing should be stable and the 

gland nuts should remain tight. The “three day” recommendation is based 

on ensuring that enough time has elapsed to ensure the packing has 

reached temperature, and has fully relaxed, while also making sure the 

time frame is short enough that the packing should have remained leak 

free. Based on operating or maintenance requirements, the “three day” 

guideline can be deviated from provided the packing gland has reached 

operating temperature at least one time. This typically happens when a 

plant is started up, and has to be shut back down due to some problem. 

Since the valve has reached operating temperature, and has gone through a 

temperature cycle or mechanical operation, the packing gland can be 

retightened without waiting the three days. 

4.2 Existing Installations 

When a packing failure (blowout or severe leak) results in a plant shutdown or 

slowdown, it is the ERM’s responsibility to commission a team to investigate the 

reason for failure. Engineering and inspection shall assess the condition of the 

valve and associated process conditions and advise investigation team of findings. 

Packing shall be selected in accordance with Appendix I. Clippertech or Rock 

Hard can be used on the end rings when packing extrusion is a problem (such as 

the stuffing box is too deep), or to take up volume so the number of “seal rings” is 

limited to five. Refurbished valves must comply with Appendix I. 

NOTE: Generally, if a gap of more then .020 exists at the bottom of the stuffing 

box between the stem and valve body, or between the packing follower and stem 

or packing follower and stuffing box, a ring of Clippertech or Rock Hard should 

be used to eliminate any possibility that the packing can extrude out of the 

packing gland. 
VALVE PACKING SPECIFICATION TEMPLATE 

5 

5.0 REPLACEMENT OF PACKING IN VALVES 

5.1 Procedure 

1) VALVE PACKING MUST BE INSTALLED IN ACCORDANCE WITH 

THE PROCEDURES OUTLINED IN APPENDIX II. (Appendix II is a standalone document for attachment to work orders.) THE FOLLOWING IS ONLY A 

BRIEF ABSTRACT. Before replacing the packing, the old packing must be 

thoroughly removed. The old packing should be examined for any unusual wear, 

burning, extrusion or excessive compression. The stem and stuffing box should 

be inspected for scoring, corrosion or other notable features. If any defects are 

found (pitting, scoring or wear per mechanics training), the defective item must be 

repaired to within manufacturers tolerances or replaced. Appendix II outlines a 

special cut for the packing. The cut seams shall be placed in the stuffing box in a 

staggered manner, as described in Appendix II. The valve shall be stroked five 

times, and the packing gland retightened before the valve is tested or returned for 

service. Usually, packing will compress further after the valve has been put into 

service. 

2) Generally, stuffing boxes should not contain more than five rings of graphite 

packing due to excessive relaxation problems. This does not include the top and 

bottom Clippertech or Rock Hard rings. Valves with deeper stuffing boxes will 

require more Clippertech or Rock Hard rings in the stuffing box. Arrangement of 

rings and packing is further described in Appendix II. 

3) All nuts MUST BE checked during routine maintenance to make sure the nuts 

can be threaded all the way down using just the fingers. If any resistance is 

encountered, the eye-bolt, stud and or nut threads should be repaired (taps and 

dies) or the component replaced. 

4) All packing gland studs and eye-bolts must be well lubricated with a good AntiSeize. Jet-Lube 550 is recommended. 

5) It is imperative that all valves have the packing glands retightened three days after 

they are back in service. Orange MFG-7262 tags indicating that the valve must 

be retightened three days after being put into service shall be affixed to the valve. 

The orange tags are not to be taken off until the valve has been retightened and 

approved by the responsible supervisor. An example of an orange MFG-7262 tag 

is found in Appendix III. 

6) Affix a metal tag on the valve with wire indicating the name of the company that 

repacked the valve, the name of the packing installed, and the date. 

 Company Name 10/05 (date) 

 o 1303 / 2000 (packing) 
VALVE PACKING SPECIFICATION TEMPLATE 

6 

6.0 STOPPING VALVE PACKING LEAKS ON LIVE EQUIPMENT 

1) If a packing leak is encountered on a valve that is in operation, and if it is 

safe to do so, an attempt can be made by a trained mechanic (or other 

qualified person) to stop or reduce the leak by tightening the packing 

gland studs. 

2) Hand wrenches should only be used on packing gland nuts. (It is very 

hard to break a stud with a hand wrench due to the limited amount of 

leverage designed into the tool.) "Cheaters" or extension bars should 

never be used. 

3) If the nut stops turning while using a hand wrench and the packing gland 

is still leaking, alternate leak sealing methods (like injection) should be 

strongly considered and encouraged. Mechanics are encouraged not to 

over tighten studs in an attempt to stop a leak. 

4) If possible, consider having an operator back-seat the valve before 

tightening the packing gland. This reduces the risk and severity of a leak 

should something go wrong while trying to tighten a packing gland on a 

live piece of equipment. 

5) A well thought out contingency plan should be documented and 

communicated prior to the tightening operation, in case the leak cannot be 

stopped or becomes worse, necessitating a plant shutdown. At a 

minimum, have an operator with a radio standing by during the tightening 

operation. 

7.0 ATTACHMENTS 

Appendix I Packing Selection for Valves

Appendix II Procedure for Installing Packing in Valves

Appendix III Valve Tag 

Appendix IV Valve Test Procedure 
APPENDIX I 

PACKING SELECTION FOR VALVES 

1 

LEGEND OF PACKING MATERIALS 

Code 

Letter 

Packing 

Type 

Ordering Description & 

Construction 

pH 

Range

Temp 

Limit 

Max. 

Press 

G Braided 

Carbon and 

Graphite (see 

notes below) 

Shall contain 98.5% carbon 

minimum, zinc powder corrosion 

inhibitor (cooled externally after 

braiding) and 50 ppm leachable 

chlorides max. 1303fep contains 

up to 7% Teflon. 

0-14 -350F 

to 

850F, 

1200F 

Steam 

4,500 

psi 

T Braided PTFE 

(Fluorotech 

by 

Graphaseal) 

Shall contain 100% PTFE 

(Teflon) and be free of graphite 

lube and binders. Ring 

constructions to be interbraided 

weave. NOTE: Special PTFE 

packing is required for Oxygen 

service. Call the equipment 

manufacturer. Please see notes 

below.

0-14 -100F 

to 

450F 

3,000 

psi 

Approved New Valves with OEM Packing

For valves that are approved for use in fugitive emission designated services, refer to the 

“(VOC)” designation in the Approved Valve Manufacturers List. The “VOC” designation is 

given to valve manufacturers that have passed the Valve Package Fugitive Emission 

Qualification Test and/or API 622. 
APPENDIX I 

PACKING SELECTION FOR VALVES 

2 

Approved Packing for New or Rebuilt Valves

For manually operated valves, the following packings are approved for all hydrocarbon, steam 

and water service process temperatures between -300°F and 800°F with a maximum pressure of 

4,500 psi. It can also be used in nonoxidizing acid service, but for consistency, Fluorotech is 

recommended for all acids. 

• Two rings each of Garlock 1303fep top and bottom of a single ring of JM Clipper 

CW2000 or Garlock 1333G. 

• Teadit style 010-ELE, which is a two braid combination packing like Garlock’s 212ULE. 

• Teadit style GAX-2236 which is a single braid packing. Note that with this packing, the 

stuffing box stud loads will need to be doubled (ie, many manufacturers recommend 20 

Fp’s so tighten to 40 Fp’s). However this added stud stress will not impact stem friction. 

See data below: 

RM Graphaseal’s Fluorotech is approved for oxidizing acid service between -100F and 500F, up 

to 3,000 psi in manually operated valves. (Oxidizing acids include nitric acid and sulfuric acid.) 

For valves that are repacked, place a metal tag on the valve indicating the name of the company 

that repacked the valve and the name of the packing that was installed. 
APPENDIX I 

PACKING SELECTION FOR VALVES 

3 
APPENDIX I 

PACKING SELECTION FOR VALVES 

4 

 
APPENDIX I 

PACKING SELECTION FOR VALVES 

5 
APPENDIX I 

PACKING SELECTION FOR VALVES 

6 

NOTES

1. Garlock sells their 1303fep and 1333G packing combination together in the same packing 

dispensing box. The product is called “2-1-2 ULE.” The “2-1-2” refers to the way the 

packing should be installed in a 5 ring set, and the “ULE” stands for “Ultra Low 

Emissions.” 

2. Packing stuffing box temperatures, when un-insulated, operate significantly below the 

process temperature (about 25 percent lower, depending on the valve). 

3. Flexible graphite packing is preferred over PTFE packing for services where it is 

chemically suitable. 

4. The low temperature limit for PTFE is approximately -100°F as PTFE begins to harden 

and lose sealability. The high limit for PTFE is approximately 500°F as PTFE begins to 

vaporize off above this temperature. The vapor is corrosive. However it is not 

recommended above 300F due to possible extrusion problems. 

5. All Graphite packing should contain a corrosion inhibitor to protect against long term 

galvanic corrosion. 

6. Clippertech or Rock Hard is also suitable as top and bottom end rings for applications 

where packing extrusion is a problem. 

7. All the recommended graphite based packings are primarily composed of graphite with a 

carbon, glass, or Inconel skeletal structure infused with a dense, nonporous, seamless 

jacket of flexible graphite. A corrosion inhibitor is provided to eliminate stem pitting. 

These packing products do not contain Mylar/polyester adhesive systems traditionally 

used to attach graphite tape to various carriers. They do not contain lubricants, 

adhesives, or binders which can decompose over time, allowing packing load and 

sealability to decrease. This significantly increases the chance of developing leaks. They 

also reduce stem friction and have superior load retention. 

8. Die formed rings are not recommended for valves unless there is no other option or 

solution available. Die formed rings have minimal internal strength, disintegrate quickly, 

have limited expansion, and are dependent on the top and bottom rings for support. Die 

formed rings are also more expensive, are difficult to handle in the field (stuffing box 

clearances are critical) and have a poor performance record (they are more prone to leak 

and can break apart if the valve stem chatters). 
APPENDIX I 

PACKING SELECTION FOR VALVES 

7 

VALVE PACKING SCHEDULE

SERVICE 

CLASSIFICATION SERVICE

RECOMMENDED 

PACKING 

Acids 

Acetic 

Chromic 

Hydrochloric 

Hydrofluoric 

Napthenic 

Nitric 

Phosphoric <85% 

Phosphoric >85% 

Sulfuric 

T 

T 

T 

T 

T 

T 

T 

T 

T 

Caustics 

Ammonia Solutions 

Caustic Hydroxides 

Doctor Solution 

Molten Sulfur 

Soda Ash 

Polysulfides 

G 

G 

G 

G 

G 

G 

Chemicals 

Alcohols 

Amines 

Aqua Regia 

Carbon Tetrachloride 

Detergent Solution 

Dowtherm 

Keystones 

Phenol 

S02 Liquid 

G 

G 

T 

G 

G 

G 

G 

G 

G 

Gases 

Air 

Ammonia 

Carbon Dioxide 

Carbon Monoxide 

Chlorine 

Flue Gas <15% 02 

Freon 

Hydrogen 

Hydrogen Sulfide 

Oxygen 

G 

G 

G 

G 

T 

G 

G 

G 

G 

Call Equip. Manufacturer
APPENDIX I 

PACKING SELECTION FOR VALVES 

8 

VALVE PACKING SCHEDULE

SERVICE 

CLASSIFICATION SERVICE

RECOMMENDED 

PACKING 

Gasoline Additives MTBE 

Techroline 

G 

G 

Hydrocarbons 

Crude Oil 

LPG 

Napthas 

Kerosenes 

Gas Oils 

Lube Oils 

Fuel Oils 

Asphalt 

Residuum 

G 

G 

G 

G 

G 

G 

G 

G 

G 

Polymers and Alkylates 

Alkanes 

Butane Phosphoric 

Acid 

H2SO4 Alkylate 

HF Alkylate 

Propylene Polymer 

G 

T 

T 

T 

G 

Water and Steam All waters 

Steam 

G 

G 
APPENDIX II 

PROCEDURE FOR INSTALLING PACKING IN VALVES 

1 

The importance of packing a valve correctly cannot be overemphasized. Many packing failures 

are due to incorrect installation of the packing. The following steps have been developed to 

ensure effective installation of packing in valves. 

1. BACK SEAT THE VALVE. This will prevent the stem and stuffing box from being 

damaged during packing removal. 

2. REMOVE ALL THE OLD PACKING FROM THE STUFFING BOX AND OTHER 

AREAS OF CONTACT. The old packing should be examined for any unusual wear, 

burning, extrusion, or excessive compression. If the valve includes lantern rings and/or 

carbon rings, try to remove them if possible and DO NOT THROW THEM AWAY. 

Unusual remarkable features should be brought to the attention of the ERM. 

3. CLEAN THE STUFFING BOX AND STEM THOROUGHLY. Inspect these areas and 

look for scoring, corrosion, pitting, burning, and unusual wear. Repairs should be made 

as noted or as directed by the responsible supervisor. The stem shall be polished to 

provide a smooth surface for the packing. The stem should have a smoothness of 32 RMS 

or less. The stuffing box should have a smoothness of 64-125 RMS. Excessively 

damaged parts should be replaced. Unusual remarkable features should be brought to 

the attention of the ERM. 

4. MEASURE AND RECORD STEM DIAMETER, STUFFING BOX BORE AND BOX 

DEPTH. USE THE CORRECT CROSS-SECTION OF PACKING. To determine the 

correct packing size, measure the diameter of the stem (inside the stuffing box area, if 

possible) and then measure the diameter of the stuffing box (to give the outer diameter of 

the ring). Subtract the stuffing box diameter from the bore diameter and divide by two. 

The result is the required packing size. An equation is provided below: 

Packing space = –––––––––––––––––––––––––––––––– 

5. WHEN USING COIL OR SPIRAL PACKINGS, ALWAYS CUT THE PACKING 

INTO SEPARATE RINGS. It is necessary that the rings be cut to the correct size. 

Otherwise, service life is reduced. Never wind a coil of packing into a stuffing box. 

Rings must be cut with a skive (or diagonal) joint, at an approximate angle of 45 degrees 

to achieve a maximum sealing area. The best way to cut packing rings is to cut them on a 

mandrel with the same diameter as the stem in the stuffing box area. Hold the packing 

tightly on the mandrel, but do not stretch excessively. Cut the ring and insert it into the 

stuffing box, making certain it fits in the packing space properly. Each additional ring 

can be cut in the same manner, or the first ring can be used as a master from which the 

balance of the rings is cut. Use a miter board so that each successive ring can be cut at 

the correct angle. 

6. INSTALL ONE RING AT A TIME. A packing set of five rings is recommended for 

most installations. (See Appendix II or the drawing below for approved packing 

stuffing box diameter – bore diameter 

2
APPENDIX II 

PROCEDURE FOR INSTALLING PACKING IN VALVES 

2 

materials and installation configurations.) Make sure cut ring of packing is clean, and has 

not picked up any dirt in handling. Lubricate the inner diameter of each ring lightly. 

Seat rings firmly (except PTFE filament and graphite yarn packing, which should be set 

snuggly, then tightened gradually). Joints of successive rings should be staggered and 

kept at least 90 degrees apart. Each individual ring should be compressed 25 percent 

with a tamping tool. When enough rings have been individually seated so that the nose 

of the packing follower will reach them, the packing follower can be used to supplement 

individual tamping. 

Deep Stuffing Boxes: If the stuffing box is deep and more rings are required, utilize as 

many Clippertech or Rock Hard rings as necessary at the top and bottom of the box to 

reduce the spool packing rings to five or six. OR install bushing spacers in lieu of 

Clippertech or Rock Hard. OR if lantern rings are provided, make sure that the lantern 

rings are installed under the lubrication port. Packing should be placed underneath the 

lantern rings. If the lantern rings are broken, inoperable, or they do not allow for proper 

arrangement of packing, contact the ERM. 

Shallow Stuffing Boxes: If the stuffing box does not allow for the recommended 

three-five packing rings, contact the OEM for packing specifications or the ERM. 

Packing Extrusion: If packing extrusion is a problem, use one layer of Clippertech or 

Rock Hard packing for the top and bottom rings to prevent packing extrusion. 

7. AFTER THE LAST RING IS INSTALLED, bring the packing follower down on the 

packing and tighten the entire packing gland. Do not jam the packing into place by 

excessive loading. If the valve includes lantern rings, make sure that they are well 

lubricated. 

8. Stroke the valve five times before start up and retighten. 

9. Affix an orange retorque tag to the valve. The valve must be retorqued three days 

after plant startup. The orange retorque tag cannot be taken off of the valve until 

the valve has been retorqued.

10. Affix a metal tag on the valve indicating the name of the company that repacked the 

valve, the name of the packing that was installed, and the date. 

 Company Name 10/05 (date) 

 o 1303 / 2000 (packing) 

A diagram of a packed gland is provided below. 
APPENDIX II 

PROCEDURE FOR INSTALLING PACKING IN VALVES 

3 

The mechanical pressure curve above shows eight packing rings. The first five rings do 

the majority of the sealing. This is the configuration that will be found in most valves. 

The bottom three do little sealing, but may be needed to fill the rest of the available 

space. The advantage of using fewer rings is less rod wear and less packing relaxation. 

Also, the stuffing box design is simpler and takes less material. The 6th, 7th, and 8th 

rings (if needed) could be substituted with bushings (or Clippertech or Rock Hard) if the 

valve has a deep stuffing box. If the stuffing box takes fewer then five rings, eliminate 

the bottom ring of 1303FEP for four ring sets, and the top and bottom rings for three ring 

sets.

Figure 1, Valve Stem and Stuffing Box 

Stud

70% Wear

1 2 3 4 5 6 7 8 

80% of Sealing 

99.8% of Sealing 

90% of Sealing 

97% of Sealing 

These rings are not 

needed 

Sealing Gradient, 0 to 

99.8% 

Shaft/Stem

Packing Follower Valve Body

Packing

Combo Packing 

Center Ring

Combo Packing End 

Rings 
APPENDIX III 

VALVE TAG 

1 

ORANGE RE-TORQUE TAG 

. 

ATTENTION: The packing gland 

MUST BE RE-TIGHTENED 3 DAYS

after it has been operating at normal 

process conditions. 

 

 Date Installed ___________________ 
APPENDIX IV 

VALVE TEST PROCEDURE 

1 

Valve Packing Fugitive Emission Qualification Test Procedure 

1.0 SCOPE AND PURPOSE 

This is a mandatory test of “off the shelf valves” (meaning out of general stock) for any 

valve manufacturer interested in being on the approved valve list for VOC services. 

Results are subject to review and approval by __________ before any valve will be put 

onto the approved list. Costs for the tests are the responsibility of the valve and/or 

packing manufacturers. Testing Facilities must be reviewed and approved by 

__________. 

This procedure is designed to be the standard by which all valve and valve packing 

systems will evaluated by __________. The objective of this test is to allow direct 

comparisons between packing and valve manufacturers so the best performing products 

can be selected that will provide the lowest level of VOC emissions. The issue of 

fugitive emissions has and will continue to be a major factor in valve and packing system 

selections. 

Once test results are available for a valve and packing type, these results will stand as the 

official results and the test will not need to be repeated unless packing changes are made, 

or any changes are made to the valve that effects the bonnet seal, packing or other sealing 

component that can result in leakage of the valve contents to the atmosphere. If 

improvements are made to a valve or packing, new test results that reflect that change 

will become official once those changes are included in the valves that are being 

produced for the open market. 

2.0 BASIC TEST PARAMETERS 

• Test Media Methane gas 

• Test Pressure 600 psig 

• Test Temperature 500 degrees F at the stuffing box 

• Heating Rate 70F to 350F, 115 degrees per hour, 

350F to 500F, 83 degrees an hour 

• Time for open/close cycle 60 seconds, 15 second rest between cycles 

• No. of Cycles 5,000 fully open to fully close, or until 500ppmv is 

reached the third time 

• Number of cycles per day 500 

• Test Valve ANSI Class 300, API 600, NPS 4, Carbon Steel Gate 

Valve 

• Leak detection method EPA Method 21 

• Max. emission (ppm) 500 PPMv static with data provided on dynamic 

measurement 

• Leak detection frequency Every 100 cycles after valve has set for two minutes 

(static) and upon the resumption of cycling (dynamic) 

• Torque to Open and Close Every 100 cycles, either by hand or electronically 
APPENDIX IV 

VALVE TEST PROCEDURE 

2 

• Minimum number of Tests Two for each valve manufacturer, one on the Valve’s 

OEM packing, one on an approved spool packing 

used for field repacks (Repack Test). Testing with 

two rings of Garlock 1303FEP above and below a 

single ring of JM Clipper CW-2000 packing, or 

Garlock’s 2-1-2 ULE packing will be required at this 

time. Other packings or packing systems may be 

approved or requested in writing by __________. 

Two tests are required to evaluate a packing or 

packing system (Repack Test on a new valve, 

specified by __________). 

3.0 TEST APPARATUS

3.1 Testing shall be performed in a test fixture that will retain the valve during 

multiple cycling while under pressure. There shall be no modifications/alterations 

of the valve from its original design and mode of operation. 

3.2 The test valve shall be installed in the orientation which causes maximum 

displacement of the stem to occur. For this test the stem shall be in the horizontal 

position and the port vertical. To facilitate testing, a power (motor or pneumatic) 

actuator may be used to open and close the valve. The actuator shall be supported 

independently from the valve and connected to the valve using a flexible shaft and 

clamp on assembly to the hand wheel. 

3.3 The shop performing the test shall prepare a schematic diagram of the test system 

and submit it to ________ for review prior to the test. It shall show the test valve 

and piping system, methane source and heater, pressure gauges and regulators, 

thermocouples and placements, safety devices, etc. Digital pictures of the test 

stand shall also be submitted. 

3.4 The piping or tubing that supplies the Methane gas shall include a flow restrictor 

that will limit the leakage rate to a ppm below that which will support 

combustion. Other flow restricting methods may be used with ________ 

approval. 

3.5 Testing facility will insure that proper fire protection systems are in place and that 

proper procedures are in place to mitigate the risk of a fire or other mishap. 

4.0 TEST VALVE 

4.1 The test valve shall be a standard production valve made in accordance with API 

600. Valve shall be a NPS 4, ANSI Class 300 gate valve and shall be new. The 

valve shall be selected from vendor “off-the-shelf” inventory by a ________ 

representative. 
APPENDIX IV 

VALVE TEST PROCEDURE 

3 

4.2 Stem diameter and stem finish measurements shall be taken before cycling is 

started, from the area of the stem that is in the center of the packing stack and 

above the follower when the valve is normally closed, by opening the valve to 

expose the stem. (Two measurements are required so they can be compared.) 

The test valve shall be disassembled and the valve stem and stuffing box shall be 

dimensionally checked as outlined below after the initial test on the valve’s OEM 

packing has been completed. The following information shall be recorded and 

provided in the final report. 

Stem: Measure stem circularity and taper in the area in contact with the packing, 

and above and below the area of the stem that has contacted the packing. Record 

how the stem is attached to the gate and the amount of side to side play in the 

stem after the packing has been removed and when the valve is half open. Stem 

side to side measurements should be made at the top of the packing gland with the 

follower pulled up. Count the number of full turns on the hand wheel to open the 

valve from fully closed to fully open. Measure stem straightness and surface 

finish. 

Stuffing Box: Measure stuffing box depth, ID, and surface finish. 

Follower: Check to see how high the packing has extruded up the stem between 

the stem and follower. Measure the follower ID, OD and height. 

Packing Gland Follower Studs: Record the stud size and threads per inch. 

Diametrical Clearance: Measure the diametrical clearances between the stem 

diameter and stuffing box ID, stem diameter and gland follower ID, gland 

follower OD and stuffing box ID. 

Pictures: Provide at least three digital pictures, one before the valve is opened 

up, one of the top of the bonnet, stem, hand wheel and packing gland, and one of 

the inside of the bonnet showing where the stem comes through, the gate and the 

attachment between the stem and gate. 

5.0 PACKING INSTALLATION 

5.1 For the Repack Test using spool packing or other requested packing system, the 

stuffing box shall be prepared for a maximum of five rings. Unless specified 

otherwise by the packing manufacturer, all five rings should be the same material. 

If the second test will include the use of die-formed rings, a maximum of two 

wiper rings (top and bottom) and not more than three middle die-formed rings 

shall be used. If the stuffing box is deeper than a five-ring set, a split bushing 

made of carbon steel and having the same ID and OD as the gland follower shall 

be installed to fill the excess depth of the stuffing box. Record the depth of the 

stuffing box with and without the split bushing. The bushing should be placed in 

the bottom of the stuffing box. 
APPENDIX IV 

VALVE TEST PROCEDURE 

4 

5.2 The test packing shall be procured from normal distribution. If braided packing is 

used, the packing rings shall be cut from a spool. The ends shall be cut at a 

45 degree angle, or as recommended by the packing manufacturer, and the cut 

ends shall be at least 90 degrees apart. 

5.3 The test facility shall install the packing in accordance with the manufacturer’s 

written instructions. The packing manufacturer may not verbally or otherwise 

assist the test facility personnel in installing the packing. 

5.4 Install the packing rings one at a time in the stuffing box and then compress each 

ring with the gland follower. 

5.5 Record the packing size, quantity of each type of packing, packing material, 

manufacturer and brand name, 45 degrees or square cut ends, and ease of cutting 

and installation. If die-formed rings are used, note in the test documentation 

whether the rings are endless or split and the density. After the packing is 

completely installed per the written instructions, record the follower height. This 

will be used to measure the packing gland movement later if adjustments are 

made to stop a leak during pressurization and cycle tests. Refer to paragraph 

6.3.5. Stoke the valve five times and rerecord the follower height. 

6.0 TEST PROCEDURE

6.1 Test Setup 

6.1.1 Verify that the valve stem is not back-seated when the valve is in the open 

position. It can be up to 3/8” off the backseat position. In the close 

position, the valve wedge can be up to 3/8” from the full close position. 

6.1.2 Verify that the cycle counter is operating properly. 

6.1.3 Ensure that the valve stem nut is lubricated properly. Lubricate the yoke 

with high temperature grease, and re-lubricate it every 500 cycles. 

6.1.4 Ensure that the heaters, thermocouples, and temperature controller are 

operating properly. 

6.1.5 Any adjustment to the test set-up after cycling is started shall be recorded. 

6.1.6 Record the packing gland nut torque and follower height, then remove the 

nuts and lubricate the threads with Jet-Lube 550 anti-seize. Make sure the 

nuts can be completely run down using only the fingers. Clean the OD of 

the follower to ensure it will slide smoothly into the stuffing box. Then 

re-torque the nuts to the value given in the manufacturers written 

instructions. If the nuts can’t be run down with the fingers, clear the 

threads or chase them with a die or tap until the nuts run freely. 
APPENDIX IV 

VALVE TEST PROCEDURE 

5 

6.1.7 Operate the value for five precycling strokes and then verify that the gland 

nuts are still at their required torque as defined in the step above. Tighten 

if needed. Record the follower height and the torque to open and close the 

valve. 

6.2 Pressurization 

6.2.1 Prior to opening the methane supply valve, with the supply system 

depressured and sealed up, zero out the PPMv background by zeroing out 

the measurement instrument. The PPMv readings that are recorded should 

be above the background reading. 

6.2.2 Pull a vacuum on the valve body and cavities before pressurizing the valve 

with methane. Then pressurized the valve with methane gas, 98 percent to 

100 percent methane gas by volume, per EPA Method 21. The test 

pressure and temperature shall not exceed the pressure/ temperature charts 

for standard class valves as shown in ASME B16.34. 

6.2.3 Check for leaks in the test apparatus and valve body joints and eliminate 

any leaks that are found. 

6.2.4 Prior to cycling the valve, a sniff test in accordance with EPA Method 21 

shall be performed in the stem and stuffing box area. The packing nut 

torque reading shall be taken and recorded at this time.

6.3 Cycle Test 

6.3.1 The valve shall be cycled from fully closed to fully open (see paragraph 

6.1.1). A full cycle shall consist of starting the valve from the closed 

position, opening the valve to open, and returning to the close position. 

The valve will be cycled starting at room temperature at the rate of one 

cycle every 75 seconds. The pause between open and close, and close and 

open operation, shall be distributed evenly. Record the amount of time it 

actually takes for the valve to cycle from closed to open. 

6.3.2 Leak readings shall be taken in accordance with EPA Method 21, using a 

calibrated Foxboro OVA 128 instrument. Leak readings shall be taken 

according to the schedule published below. All readings shall be taken in 

still air with the ventilation fan off. Also leak check the bonnet gasket 

area to make sure this gasket is not leaking and record the measurement in 

PPMv. Testing at the end of each day will be stopped 10 cycles short of 

500 cycles, so the final leakage measurement can be made at the start of 

the next day on the 500th cycle. 

6.3.3 Two readings shall be taken at each leak test interval, when the valve stem 

is in the static position (not moving) and when the stem is in the dynamic 
APPENDIX IV 

VALVE TEST PROCEDURE 

6 

(moving) position. The static reading shall be taken when the valve is in 

the closed position and the dynamic reading shall be taken when the stem 

is in motion during the opening stroke following the static reading. 

Readings shall be taken by positioning the probe on the topside of the 

stem against the follower. Wrap the area encompassing the follower with 

foil to capture any leakage from the seals OD and ID. Since the methane 

will rise, the probe is placed on the topside of the stem. Leakage is 

recorded 1 time per second for 60 seconds. The average and maximum 

values are then calculated and reported. The static reading shall be taken 

after the valve stem has been allowed to sit stationary for two minutes. 

Record both readings. 

6.3.4 The stuffing box should be preheated to 90F. Ten thermal cycles shall be 

performed over the 5,000 cycle test, with one every 500 cycles. A thermal 

cycle consist of heating the valve’s packing gland to 500F, holding the 

temperature at 500F for approximately 100 cycles, and then cooling it 

back down to 70-90 deg. F. The valve body should be heated and 

insulated enough that it does not act as a heat sink, but the critical 

temperature to monitor is the outside center of the packing gland. 

6.3.5 When the static leak rate exceeds 500 ppm, adjust the packing to zero ppm 

reading, or as low as possible, and continue the cycle. Record the number 

of cycles and ppm reading at this point. The torque required to retighten 

the packing nuts shall be measured and recorded. If the static leakage 

does not drop below 50 PPMv using the manufacturer’s recommended 

torque, the nut torque should be increased to 1.5 times the recommended 

level. If the static leakage is still above 50 PPMv, the nut torque shall be 

increased to two times the recommended level. The nut torque is limited 

to 200 percent of the original recommended torque. Record the follower 

height after the adjustment has been made. Continue the test until the 500 

ppm leak level is reached the third time. At this time terminate the test. 

Record the static and dynamic leakage rates in ppm and the number of 

cycles. 

6.3.6 Record operating torque on the valve every 100 cycles, for both the 

opening and closing cycles, and before and after any adjustments (if 

needed). Torque measurements can be made electronically with a stain 

gage or by hand with an appropriate torque wrench. Closing torques are 

limited to a 200 pound pull force on the handwheel. The allowable torque 

is calculated as 200 pounds times the radius of the handwheel in feet. If 

the allowable torque is exceeded, the test shall be ended. 

6.3.7 After the first 30 cycles, when the valve is about 160F, take the first 

leakage measurement, then adjust the packing gland nuts back to the 

original recommended torque level. Record the follower height after the 

original torque is reached. 
APPENDIX IV 

VALVE TEST PROCEDURE 

7 

6.3.8 The cycling test is designed to take ten days, with each 500 cycle block 

taking approximately 11 hours. The chart below outlines an approximate 

schedule, showing elapsed time, temperatures and hold points. The 

controller should be set to stop cycling the valve every 100 cycles so 

leakage measurements can be made. The temperature should also be held 

until the measurements are completed. This way, if it takes slightly more 

time to complete leakage measurement, the schedule can be easily 

adjusted. 

7.0 TEST RESULTS 

The test results, both static and dynamic readings, shall be plotted on a chart, leakage in 

ppm on the vertical axis and number of cycles in the horizontal axis. The number of 

cycles and ppm readings in each packing adjustment shall be shown on the chart. The 

chart must be in Microsoft Excel (XL) format (see below). 

________ reserves the right to use the test results in any manner necessary in the 

conducting of its business. Data will not be released outside ________ where the names 

of specific valve or packing manufacturers are tied to specific test results unless 

________ has paid for the test or the company purchasing the testing gives written 

permission. The testing facility shall not release any test results without the written 

approval of the company purchasing the testing. 

8.0 POST-TEST VALVE AND PACKING INSPECTION 

After the tests, the valve shall be disassembled and the parts inspected. The same 

measurements as previously taken on the stem, stuffing box, gland follower, etc., shall be 

taken again and compared to the previous measurements. Record any evidence of 

wearing on these parts, including digital pictures, especially on the stem. If no change in 

measurements can be detected, the same valve and stem can be used for the second test. 

If the stem is damaged or worn, it should be replaced prior to starting the next test. 

 

Approx. Test Time (hours) Cycle Number Set Temp

0.0 0 70 

0.7 30 145 

2.2 100 320 

4.3 200 500 

6.5 300 500 

8.7 400 320 

10.8 500 70 
APPENDIX IV 

VALVE TEST PROCEDURE 

8 

9.0 DOCUMENT SUBMITTAL 

Results of the leakage readings in graph form, measurements taken on the valve, packing 

torque readings and other information required by this procedure shall be placed in a 

Microsoft Excel file and submitted to ________ at the address below. It is preferred that 

the documents be e-mailed. 

Name: 

E-Mail Address: 

Street: 

City: 

Office Phone: 

FAX: