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 Specificati on 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, Machin e 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 LE AKS ON LIVE EQUIPMENT ................................ 6

7.0 ATTACHMENTS .............................................................................................................. 6 Appendix I Packing Selection for Valves Appendix II Procedure for In stalling Packing in Valves Appendix III Valve Tag Appendix IV Valve Test ProcedureVALVE 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 Inst ruction recognizes th at most pump and rotating equipment have been converted to mechanical seals. (Some water pumps still use packing.) This Instruction is also reco mmended for all services to minimize leakages to the environment.

If a packing application is not specified be low, contact the equipment reliability manager or designated representative, or appropriate supervisor fo r guidance. Make sure the correct packing and method is used in each application to ensu re compliance with environmental laws, and to provide reliabl e, leak free operation of equipment.

In case of conflict between this Instructi on and Corporate Standa rd 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 Orga nic Compound) that ar e 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 envi ronmental representative for additional details.

3.0 RESPONSIBILITIES

3.1 Equipment Reliability Manager (ERM ) or Designated Representative

1) Keeps this Instruction, including the packing selection ch arts, 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 test ed by independent outside labs before the packing can be considered for use in the refinery. The ERM shall indicate which tests must be administ ered and will set the requirements for acceptability of the new packing. Thes e tests must be standardized and allow for a comparison between competing products. Refer to the “Valve & Packing Testing Procedure” in Appendi x V. (Tests are currently being conducted at Yarmouth Research in Ma ine.) The ERM shall prepare theVALVE PACKING SPECIFICATION TEMPLATE

2 appropriate engineering, MOC, pur chasing specifications and the appropriate training for handling and installation of th e 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, includ ing control valve packing.

3.2 Project Engineer

1) Follows this standard’s requirement s for new and rebuilt valves for both maintenance and capital projects. Informs ERM or their designated representative when problems are enc ountered in the field or to seek guidance on special applications th at fall outside this Instruction.

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

1) Confirms that the mechanics ar e 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 th is 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. ma terial 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 en countered 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 depende nt 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 st em, cross-section of packing, temperature, pressure, type of equipment, equipment materi als, packing materials, number of packingVALVE 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 ope rating conditions of the equipment in accordance with Appendix I. If unus ual conditions arise, consult the ERM. In extremely difficult or h azardous cases, the project engineer should consult with the packing ma nufacturer to determine the proper packing and either the Company or th e packing manufacturer should make preliminary tests. (See Section 3.1, item 4.)

2) New valves with Original Equipm ent Manufacturer (OEM) packing must be listed in the approved valve manu facturers list (AVML) and designated “VOC” approved before the valve ente rs 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 A ppendix 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 pack ing 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 w ith five rings of packing and the remaining space filled with Clippert ech or Rock Hard as shown in Appendix II, Figure 1.

5) All new valves must have the pack ing 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 b ack off on the packing gland nuts for shipping to protect the packing ri ngs from possible extrusion which isVALVE PACKING SPECIFICATION TEMPLATE

4 why all packing gland nuts must be ch ecked for tightness right after the valve is installed.

Waiting “three days” before doing a reti ghtening 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 pack ing gland has fully reached operating temperature before the gland is retig htened. It generally takes about 24 hours before the packing has fully rela xed in valves that have been left at a steady state condition and not operated. Thermal-cycles and mechanical operation of valves can also induce relaxa tion before the packing has been retightened. After the retightening, provided it has been done properly and at the co rrect time, the packing s hould 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 maintena nce requirements, the “three day” guideline can be deviated from prov ided 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 wa iting the three days.

4.2 Existing Installations

When a packing failure (blowout or seve re leak) results in a plant shutdown or slowdown, it is the ERM’s re sponsibility to commission a team to investigate the reason for failure. Engineering and insp ection shall assess the condition of the valve and associated process conditions and advise inves tigation team of findings. Packing shall be selected in accordance with Appendix I. C lippertech 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 th at 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 INST ALLED 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 th e packing, the old packing must be thoroughly removed. The old packing shoul d be examined for any unusual wear, burning, extrusion or excessive compressi on. The stem and stuffing box should be inspected for scoring, corrosion or othe r 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 Appendi x II. The valve shall be stroked five times, and the packing gland retightened befo re the valve is tested or returned for service. Usually, packing will compress fu rther after the valve has been put into service.

2) Generally, stuffing boxes should not contai n 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 ju st 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 MF G-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 o ff 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.) "C heaters" or extens ion bars should never be used.

3) If the nut stops turning while usi ng a hand wrench and the packing gland is still leaking, alternat e 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 redu ces 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, necessi tating a plant shutdown. At a minimum, have an operator with a ra dio standing by during the tightening operation.

7.0 ATTACHMENTS

Appendix I Packing Selection for Valves

Appendix II Procedure for In stalling Packing in Valves

Appendix III Valve Tag

Appendix IV Valve Test ProcedureAPPENDIX 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 fug itive emission designated services, refer to the “(VOC) ” designation in the Approved Valve Manufact urers 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 pa ckings are approved fo r 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 si ngle braid packing. Note that with this packing, the stuffing box stud loads will need to be doub led (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 oxi dizing acid service between -100F and 500F, up to 3,000 psi in manually operated valves. (Oxidizing acids include nitric aci d 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

3APPENDIX I PACKING SELECTION FOR VALVES

4APPENDIX I PACKING SELECTION FOR VALVES

5APPENDIX I PACKING SELECTION FOR VALVES

6 NOTES

1. Garlock sells their 1303fep and 1333G packing co mbination 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” st ands for “Ultra Low Emissions.”

2. Packing stuffing box temperatures, when un-in sulated, operate significantly below the process temperature (about 25 per cent lower, depending on the valve).

3. Flexible graphite packing is preferred ove r 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 lim it for PTFE is approximately 500 ° F as PTFE begins to vaporize off above this temperature. Th e vapor is corrosive. However it is not recommended above 300F due to possible extrusion problems.

5. All Graphite packing should contain a corrosi on inhibitor to protec t 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 structur e infused with a dense, nonporous, seamless jacket of flexible graphite. A corrosion inhibitor is provided to elimin ate 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 decom pose over time, allowing packing load and sealability to decrease. This significantly in creases the chance of developing leaks. They also reduce stem friction and ha ve 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 mi nimal 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 di fficult to handle in the field (stuffing box clearances are critical) and have a poor perf ormance record (they ar e 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. ManufacturerAPPENDIX 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 GAPPENDIX II PROCEDURE FOR INSTALLING PACKING IN VALVES

1 The importance of packing a valve correctly can not be overemphasized. Many packing failures are due to incorrect installation of the packing. The following steps have been developed to ensure effective installati on of packing in valves.

1. BACK SEAT THE VALVE. This will prev ent the stem and stuffing box from being damaged during packing removal.

2. REMOVE ALL THE OLD PACKING FROM TH E STUFFING BOX AND OTHER AREAS OF CONTACT. The old packing sh ould 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 T HOROUGHLY. Inspect these areas and look for scoring, corrosion, pitting, burning, and unusual wear. Repairs should be made as noted or as directed by th e responsible supervisor. Th e 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 DIAM ETER, 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 th e 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 si ze. An equation is provided below:

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

5. WHEN USING COIL OR SPIRAL PA CKINGS, ALWAYS CUT THE PACKING INTO SEPARATE RINGS. It is necessary that the rings be cut to the correct size. Otherwise, service life is reduced. Neve r wind a coil of packing into a stuffing box. Rings must be cut with a skive (or diagonal) joint, at an approxima te 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 excessi vely. 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 ri ng 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 s tuffing box diameter – bore diameter

2APPENDIX II PROCEDURE FOR INSTALLING PACKING IN VALVES

2 materials and installation configur ations.) Make sure cut ring of packing is clean, and has not picked up any dirt in handling. Lubricat e the inner diameter of each ring lightly. Seat rings firmly (except PTFE filament a nd 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 i ndividual ring should be compressed 25 percent with a tamping tool. When enough rings have b een 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 mo re rings are requ ired, utilize as many Clippertech or Rock Hard rings as n ecessary at the top a nd bottom of the box to reduce the spool packing rings to five or si x. OR install bushing spacers in lieu of Clippertech or Rock Hard. OR if lantern ri ngs are provided, make sure that the lantern rings are installed under the l ubrication 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 packi ng, 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 botto m 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 gla nd. Do not jam the packing into place by excessive loading. If the valve includes la ntern 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 th e 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. Th is 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 bus hings (or Clippertech or Rock Hard) if the valve has a deep stuffing box. If the stuffi ng 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

Stu d

70% Wea r

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 Packin g Followe r Valve Bod y

Packin g

Combo Packing

Center Rin g Combo Packing End RingsAPPENDIX 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 revi ew and approval by __________ before any valve will be put onto the approved list. Costs for the tests ar e the responsibility of the valve and/or packing manufacturers. Testing Faciliti es must be reviewed and approved by

__________. This procedure is designed to be the st andard by which all va lve and valve packing systems will evaluated by __________. The objective of this test is to allow direct comparisons between packing and valve manuf acturers so the best performing products can be selected that will pr ovide 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 th e valve that effects the bonnet seal, packin g 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 degr ees 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 resumpti on of cycling (dynamic)

• Torque to Open and Close Every 100 cy cles, either by hand or electronicallyAPPENDIX 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 (Rep ack Test). Testing with two rings of Garlock 1303FEP above and below a single ring of JM Clippe r 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 facilita te testing, a power (motor or pneumatic) actuator may be used to ope n and close the valve. Th e 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 revi ew prior to the test. It shall show the test valve and piping system, methane source and heater, pressure ga uges and regulators, thermocouples and placements, safety devices , etc. Digital pict ures of the test stand shall also be submitted.

3.4 The piping or tubing that supplies the Me thane 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 fi re 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 pr oduction 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 measurem ents 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 nor mally 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 outline d 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 b een 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 packin g 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 di ameter and gland follower ID, gland follower OD and stuffing box ID.

Pictures : Provide at least three digital pict ures, one before the valve is opened up, one of the top of the bonnet, stem, ha nd 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 ma ximum of five rings. Unless specified otherwise by the packing manuf acturer, all five rings shoul d 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 deep er 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 bus hing. The bushing s hould 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 in stall the packing in accordance with the manufacturer’s written instructions. The packing manuf acturer may not verbally or otherwise assist the test facility pers onnel in installi ng 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 ar e used, note in the test documentation whether the rings are endless or split a nd the density. After the packing is completely installed per the written instru ctions, record the follower height. This will be used to measure the packing gland movement later if adjustments are made to stop a leak during pressurizati on 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 Set up
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 co unter is operating properly.

6.1.3 Ensure that the valve stem nut is lu bricated properly. Lubricate the yoke with high temperature grease, and re-lubricate it every 500 cycles.

6.1.4 Ensure that the heaters, thermoc ouples, and temperature controller are operating properly.

6.1.5 Any adjustment to the test set-up afte r 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 usi ng 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 gi ven in the manufacturers written instructions. If the nuts can’t be run down with the fi ngers, clear the threads or chase them with a die or tap until the nut s 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 suppl y 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 cav ities 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 ex ceed 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 r oom temperature at the rate of one cycle every 75 seconds. The pause be tween open and close, and close and open operation, shall be distributed even ly. 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 sh all 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 da y will be stopped 10 cycles short of 500 cycles, so the final leakage measur ement can be made at the start of the next day on the 500th cycle.

6.3.3 Two readings shall be taken at each l eak test interval, when the valve stem is in the static position (not moving) and when th e stem is in the dynamicAPPENDIX IV VALVE TEST PROCEDURE

6 (moving) position. The stat ic 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 reporte d. The static read ing 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, w ith one every 500 cycles. A thermal cycle consist of heating the valve’ s packing gland to 500F, holding the temperature at 500F for approximatel y 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 out side 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 poin t. The torque required to retighten the packing nuts shall be measured a nd recorded. If the static leakage does not drop below 50 PPMv using the manufacturer’s recommended torque, the nut torque should be incr eased to 1.5 times the recommended level. If the static leakage is sti ll 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 recomme nded 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 va lve every 100 cycles, for both the opening and closing cycles, and befo re 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, temp eratures 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 a nd dynamic readings, shall be pl otted 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 adju stment 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 re lease 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 disass embled and the parts inspected. The same measurements as previously taken on the st em, 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 st arting 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 70APPENDIX 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 requi red by this procedure shall be placed in a Microsoft Excel file and submitted to ________ at th e address below. It is preferred that the documents be e-mailed.

Name : E-Mail Address : Street : City : Office Phone : FAX :