Transcript Valve Packing Manufacturer

Communication
necessary to achieve
LowE valve sealing
compliance
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Presented by: Ron Frisard
AW Chesterton
Stationary Equipment Solutions
Presenter
 Ron Frisard graduated from Northeastern
University in Boston with a degree in
Mechanical Engineering technology in 1989.
Ron has worked for the A.W. Chesterton
Company for the last 25 years in all facets of
Mechanical Packing. Ron has held positions
in Application Engineering, Research and
Development, Global Training, and currently
in Global Marketing in the Stationary
Equipment Solutions group.
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Communication
 LowE Plant wide success needs
good communication between many
groups.
Many failures root causes are a
breakdown between silos
Appropriate communication is needed
from birth to grave of LowE LDAR
equipment
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Success stories of communication
 Mars Climate Orbiter
 750 lb robotic space probe launched by
NASA on December 11, 1998 to study the
Martian climate, atmosphere, and surface
changes
 The cost of the mission was $327.6 million
 On September 23, 1999, communication with
the spacecraft was lost as the spacecraft
went into orbital insertion, due to groundbased computer software which produced
output in non-SI units of pound-seconds
(lbf×s) instead of the metric units of newtonseconds (N×s) specified in the contract
between NASA and Lockheed.
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What groups new valve?
Engineering
Maintenance
Valve
Manufacturer
Valve Packing
Manufacturer
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What groups during life?
Engineering
Valve Shop
LDAR
First attempt
(LDAR/
Maintenance/
Contractor)
Valve Packing
Manufacturer
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Valve Actuation Differences
Instrumentation & Control group
Control valves
Packing Friction
Need to know limits for LowE
sealing and Packing Friction
calculations
If installing packing, need to know
Packing Manufacturer’s installation
instructions
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Valve Packing Manufacturer
API 622 testing
Sealability
Corrosion
Gland load requirements
Packing Arrangement requirements
Installation procedure
Tolerances needed
Tamping rings
Consolidation
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Valve Manufacturer / Valve Repair to API RP
621,
API 622 and API installer spec
Installing the packing
Right rings
Dimensions (tolerances)
Hydro Testing
Torque / Gland load
Warranty information
When installed date
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Gland load
Critical step needed to get LowE
Performance and long life
Torque is not tension
Accuracy of bolting condition is
critical
Valve Springs sets as load guides
Assist in monitoring load
Re-torquing in-effective at temperature
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Plant Maintenance (valve installers)
Should the valve be inspected?
Corrosion on stem
Gland force still loaded
Unless live loaded, impossible to tell
Dried Anti-seize could effect values
Has the packing been consolidated?
API 622 and API RP 621 specifically
states that the valve has been
consolidated to packing manufacturers
limits.
Does the gland bolts need to be
adjusted (Block vs. Control)
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Engineering
Plant specs on procedure for
installing valves
Specs need to bridge groups linkage
While in-service, inspection
opportunities
Large reason valves leak over time –
Loss of gland load
Walk down review of live loading heights
Preventative maintenance instead of
reactionary
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Operations
Do they adjust gland load for
any reason?
Do they do inspections and
know what to look for?
If so, need to know facts about the
valve on gland load limits.
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LDAR/First attempt
valves during monitoring
Need access to valve gland load
during first attempt
 or directing first attempt with
contractors
Big Data analysis of failure mode
Troubleshooting packing removed
Create matrix and recommend
improvements
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Repack loop
Send valve out
Valve shop
Maintenance
Purchasing
Engineering
Repack in line
Valve Packing
Manufacturer
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Engineering
Spec writing on replacement packing
Meets API 622 leakage requirements
Installation and arrangement documented
to plant spec and training
Fire safe approval
 Tracking of packing arrangement and size
Valve Drawings does not show stuffing
box
Stocking sizes (die formed vs. spool)
Issues with cutting
Bolting should be replaced
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Purchasing
Following Engineering
Specification
API 622 approval
Plant wide acceptance
Installation and arrangement
documented
Qualified, knowledgeable vendor
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Maintenance Installer
 Following engineering procedure
 Key document
 Training on how to properly install
 Cutting spacers
 Cutting rings (if needed)
 Arrangement
 Training on trouble shooting removed
packing
 Cross functional team
 Looking for failure modes
 Access to packing arrangement and gland
load requirements (torque)
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Consolidation
Major step to ensure proper leveling
of gland load
Actuate the valve multiple times
Retighten with torque wrench
 if any movement of the nuts
(consolidation), repeat actuation steps
until no movement at the recommended
torque.
The larger the packing cross section the
greater the consolidation
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Continuous improvement - Goals
Lower packing leakage rates (LDAR)
Cross functional team
Maintenance, Engineering, I&C, etc
Capture ALL packing failure
Training all groups to capture packing
coming out of valves
Fill out form to track
Look for ROOT CAUSE!!
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Cloud Software
Software can assist in keeping
groups on same page
“cloud” solutions can ensure
everyone working on same page
Engineering
Valve Shop
Purchasing
Planning
Maintenance
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Cloud solution
A good software should include
up to date access for
Packing style
Packing size
Packing Arrangement
Packing Torque
Installation date
Warranty length and end date
Testing documentation
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Remember, communication is
key between groups to ensure
LowE compliance
Thank you
Questions?
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