Section 5 — Piping

IPE-EP-5-3-23

IPE Engineering Practice IPE-EP-5-3-23

Document number: IPE-EP-5-3-23 · Section: 5 — Piping

1.0 SCOPE 2 2.0 REFERENCES 2 3.0 DEFINITIONS 2 4.0 VENDOR PROPRIETARY PACKING QUALIFICATION 2 5.0 VALVE PACKING REQUIREMENTS 4 6.0 VALVE PACKING INSTALLATION PROCEDURE 6 INFLECTION POINT ENGINEERING 6.1 General 6 6.2 Packing Removal 6 6.3 Cleaning and Mechanical Inspection 6 6.4 Valve Diametrical Clearances, Finishes, and Tolerances 6 6.5 Packing Installation 7 6.6 Installation of the Garlock Style #9000 EVSP Simplified Set 9 6.7 Live Loading Installation 9 7.0 TABLES 11 TABLE 1 VALVE PACKING MATERIALS AND DESIGN 11 TABLE 2 VALVE CLEARANCES, FINISHES AND TOLERANCES 12 TABLE 3 COMPRESSION TABLE FOR GARLOCK FIVE–RING PACKING COMBINATIONS SETS 14 TABLE 4 COMPRESSION TABLE FOR GARLOCK STYLE #9000 EVSP SIMPLIFIED SET 15 8.0 FIGURES 16 FIGURE 1 LOW CYCLE PACKING DESIGN FOR GATE AND GLOBE VALVES 16 FIGURE 2 LOW CYCLE PACKING DESIGN FOR COMPACT GATE AND GLOBE BELLOWS SEALS AND QUARTER TURN VALVES 17 FIGURE 3 HIGH CYCLE PACKING DESIGN FOR MOTOR OPERATED GATE VALVES (MOV’S)..18 FIGURE 4 PACKING DESIGN FOR COMPACT GATE AND GLOBE BELLOWS SEALS AND QUARTER TURN VALVES 19 FIGURE 5 GRAPHICAL DESCRIPTION OF VALVE CLEARANCE AND TOLERANCE POINTS 20 Inflection Point Engineering CONFIDENTIAL © 2025 Inflection Point Engineering, LLC Uncontrolled when printed or stored locally

INFLECTION POINT ENGINEERING Valve Packing 4.2 Alternative performance testing procedures may be accepted if approved by the Owner’s Engineer and all the requirements of section 4.6 are met. 4.3 Packing Performance Test Procedure for Low Cycle Packing 4.3.1 Install packing set using the recommended field installation procedure. 4.3.2 Bolt Torque and Stem Friction 1) Record bolt torque and yoke gap. 2) Determine % compression. 3) Actuate stem through 5 cycles, recording actuation force values on the 1st and 5th cycles. 4.3.3 Pressurize system to 500 psig with Helium. 4.3.4 Fugitive Emission Measurement 1) Measure emission level using EPA Method 21 and Organic Vapor Analyzer (ex. Mark Products 9822). • If < 500 ppm achieved, record bolt torque and yoke gap. • If bolt torque > 95 ft-lbs, terminate test and proceed to Step 7. 2) If leakage > 500 ppm, re–torque until either < 500 ppm is achieved or bolt torque > 95 ft-lbs (mark such adjustment with an asterisk on line graph). 4.3.5 Bring system temperature up to 750°F and perform Step 4. 4.3.6 Cycle the valve (open-to-closed-to-open) and perform Step 4 every 100 cycles until one of the following is met: 1) 1000 cycles are achieved, terminate test and proceed to Step 7. 2) If a sixth adjustment is required, terminate test record the number of cycles at which the sixth adjustment is required, and proceed to Step 7. 4.3.7 Remove system pressure and allow system temperature to cool. Once at ambient temperature, remove packing set as recommended. Record observations on packing condition and the condition of the sealing surfaces for debris build–up, wear, etc. 4.4 Packing Performance Test Procedure for High Cycle Packing 4.4.1 Install packing set using the recommended field installation procedure. 4.4.2 Bolt Torque and Stem Friction 1) Record bolt torque and yoke gap. 2) Determine % compression. 3) Actuate stem through 5 cycles, recording actuation force values on the 1st and 5th cycles. 4.4.3 Pressurize system to 500 psi with Helium. 4.4.4 Fugitive Emission Measurement 1) Measure emission level using EPA Method 21 and a Organic Vapor Analyzer (ex. Mark Products 9822). 2) If leakage > 500 ppm, re–torque until either < 500 ppm is achieved or bolt torque > 95 ft-lbs (mark such adjustment with an asterisk on line graph). • If < 500 ppm achieved, record bolt torque and yoke gap. • If bolt torque > 95 ft-lbs, terminate test and proceed to Step 7. 4.4.5 Bring system temperature up to 750°F and perform Step 4. Inflection Point Engineering CONFIDENTIAL © 2025 Inflection Point Engineering, LLC Uncontrolled when printed or stored locally

INFLECTION POINT ENGINEERING Valve Packing 5.2.5 (*)A zinc powder coating shall be applied to all rings to provide a corrosion inhibitor system. Alternative corrosion inhibiting systems are subject to the approval of the Owner’s Engineer. 5.3 (*)In addition to the requirements of the previous paragraph, the graphite die formed rings used in the Graphite Packing System shall be made from flexible 95% pure carbon graphite with no binders, lubricators or additives. Certified tests showing the carbon assay of the graphite die formed rings shall be made available to the Owner’s Engineer for review or request. After die– forming, the rings shall have a normal density of 70 lbs/cu. ft. to 90 lbs/cu. ft. 5.4 Spool rope packing may be used for emergency field installations when standard die–formed rings cannot be obtained in the time required, with approval of the Owner’s Engineer. Only Garlock 1303 is acceptable. 5.5 Bushings used to fill the stuffing box to enable the use of the five ring combination packing set for gate and globe valves, see Figures 1 and 3, shall meet the following requirements. 5.5.1 For valves installed in a vertical or near vertical position, or for valves where stem galling is not a concern, the bushing shall be fabricated from the same material as the valve trim. 5.5.2 The following bushing materials shall be used for valves with a stem configuration which may result in galling damage if the stem makes contact with the bushing. Contact of the valve stem and bushing can occur from deflection due to stem weight, stem bowing, or if the stem is not positioned in the center of the stuffing box by its backseat. 1) Nitronic - 60 stainless steel bushings, or 2) Carbon bushings. Note that carbon bushings need to be checked and replaced, if necessary, each time the valve is repacked. Bushings should last the life of the valve. 5.5.3 Machining tolerances for bushings shall be as follows. These tolerance ensure that the bushing will be “OD centered”, and that the bushing inside diameter will not make contact with the stem. 1) Bushing inside diameter: nominal stem OD +.020/+.015 inches. 2) Bushing outside diameter: nominal stuffing box bore OD -.005/-.010 inches. 5.5.4 All bushings shall be split axially. The top and bottom surfaces of each bushing half shall be drilled and tapped. 5.5.5 Bushing lengths longer than three cross–sections shall be cut into sections to facilitate installation into the valve stuffing box. Sectioning of bushings into a length equal to approximately two bushing cross sections is recommended. 5.6 Live loading of valve stem packing glands should be considered for tough sealing services in which the valve sees many thermal and/or mechanical cycles which cause consolidation and extrusion of the packing material. Otherwise, the standard 5–ring packing arrangement without live loading is sufficient. The following requirements shall be met for live loading. 5.6.1 Since there are many parameters that affect the design of belleville springs, each valve live loading situation needs to be designed per each individual case. Most major valve packing manufacturers provide a free valve survey and packing design program. 5.6.2 Belleville springs shall not be painted once in service. When paint hardens between the belleville washers, their operational spring force will be altered. If this is a problem, the springs could be encased in a housing to prevent them from being painted and protect them from corrosion. Inflection Point Engineering CONFIDENTIAL © 2025 Inflection Point Engineering, LLC Uncontrolled when printed or stored locally

INFLECTION POINT ENGINEERING Valve Packing 6.5.3 Additional requirements for valves designed to hold only five packing rings are as follows: 1) Install bottom braided ring and tamp. 2) Install two flexible graphite tape rings, tamping each into place separately. Stagger all joints 90.(cid:31) 3) Install the gland follower and compress a distance sufficient to add the next packing ring. 4) Add the fourth ring (flexible graphite tape) for gate and globe valves, third ring for quarter turn valves, and tamp into place. 5) Install the gland follower and compress a distance sufficient to allow installation of the final ring. 6) Add the fifth braided end ring (fourth ring for quarter turn valves) and tamp into place. 7) Install the gland follower and compress until bottom of gland follower has penetrated into the stuffing box a distance of 1/2 cross–section. 8) Cycle the valve stem through five complete actuations. Check for gland stud nut torque decay after each “open to close” sequence. Adjust as necessary to restore torque. 6.5.4 Additional requirements for deep boxed valves retrofitted with a bushing to reduce the box depth to that necessary for a five ring packing system area as follows: 1) After unpacking the valve, measure the Total Box Depth along bore wall surface (box OD surface) and record. 2) Using calipers, measure the stem diameter and the box bore diameter and record. Determine the packing cross–section from the following formula. Packing Cross–Section = Box Bore Diameter - Stem Diameter 3) After determining the required packing cross–section, consult Table 3 to determine the “Total Packing Set Space” required for that cross–section and record. 4) The required bushing length to fill the excess space in the stuffing box can be determined by subtracting the “Total Packing Set Space” measurement from the “Total Box Depth” measurement. The formula is: Required Bushing Length = Total Box Depth - Total Packing Set Space 5) Longitudinal bushing lengths may need to be cut into sections approximately two cross– sections long to enable installation in the box. Stagger all bushing joints by 90°. 6) Install five–ring packing set by the guidelines listed in the previous paragraph. Inflection Point Engineering CONFIDENTIAL © 2025 Inflection Point Engineering, LLC Uncontrolled when printed or stored locally

INFLECTION POINT ENGINEERING Valve Packing 6.7.2 The packing material should be installed and compressed prior to adding the belleville springs. follow procedure 6.5.1.1 and 6.5.1.6. 6.7.3 Once the belleville springs have been added and compressed to their recommended value, the valve shall be cycled through five complete actuations if possible. Make adjustments as necessary to restore spring compression until no further decay is noted. Follow procedures 6.5.1.8 to 6.5.1.11. 6.7.4 The belleville springs should be compressed to a recommended compression that exerts the packing manufacturer’s recommended maximum seating load on the packing material. This leaves room for some packing consolidation/extrusion (extension of the belleville washers) before the manufacturer’s minimum seating load is not achieved and leakage occurs. Inflection Point Engineering CONFIDENTIAL © 2025 Inflection Point Engineering, LLC Uncontrolled when printed or stored locally

INFLECTION POINT ENGINEERING Valve Packing TABLE 2 (CONT’D) VALVE CLEARANCES, FINISHES AND TOLERANCES Clearance, Finish or Tolerance Description (see Figure 4) Reformer Recond. STEM RUN–OUT New Valves (1) MOVs Valves The lessor of: The lessor of: ± 0.001 Dstem ± 0.001 Dstem Over Entire Length of Stem (L ) Inch of Stem Inch of Stem stem Length Length ± 0.030 inch or or L stem ± 0.030 inch ± 0.030 inch L L stem stem Over Stem Length ± 0.030 inch ± 0.030 inch ± 0.030 inch Contacting Packing (L ) L L L packing packing packing packing NOTES: (1) For Valve Classes 900 through 4500 and highly cycled valves, reduce diametrical clearances to 0.60 of values shown. Inflection Point Engineering CONFIDENTIAL © 2025 Inflection Point Engineering, LLC Uncontrolled when printed or stored locally

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