Mr Alan Veteto, Director - Business Dev., N. America, L&T Valves explores the impact of Stem and Stuffing Box Finish on Valve Fugitive Emissions Performance. Presented at Fugitive Emissions Summit - Americas, June 2018

1. Effects of Stem and Stuffing Box
Roughness on Valve Fugitive
Emissions Performance
Presented by Mr Alan Veteto,
Director, Business Development - North America, L&T Valves
at Fugitive Emissions Summit, Americas, June 2018

2. Presentation Overview
Trends in Fugitive Emissions
Standards on Fugitive
Emissions
Test results on different Stem
and Stuffing box surface
roughness values
2

3. Fugitive Emissions…
In simple terms,
such as Valves & pumps in an
industrial site typically a Refinery.
Emissions from Refineries and Chemical Plants can be broadly classified as
and
3

4. Automotive,
35%
Chemical,
30%
Oil & Gas,
20%
Others, 15%
Fugitive Emissions of VOCs and HAPs
Source - Selecting Environmentally Responsible Sealing Solutions, Jim Drago, P.E., Garlock
4

5. Fugitive Emissions from Valves…
• Valves are considered to account for approximately 60% of Fugitive
Emissions of a Refinery/Chemical Plant
*Source - Monitoring and Containment of Fugitive Emissions from Valve Stems, University of British Columbia, Vancouver
Valves,
60%
Valve Stem, 80%
Flanges,
Pumps, 15%
Tanks, 10%
Relief
valves, 15%
Other Joints,
20%
5

6. Valves in a Refinery….
~10,000 to 1,50,000 Valves in a Refinery*
* Source – Oil Refineries Fail to Report Millions of Pounds of Harmful Emissions,
Committee on Government Reform, U.S. House of Representatives
6

7. % of total leakers during an
EPA refinery audit
7
Percentage of Total Leaks By Component Type
0.12%
0.36%
1.23%
0.04%
0.40%
1.07%
0.63%
3.97%
15.43%
1.71%
3.89%
0.28%
0.24%
1.11%
0.16%
0.16%
0.91%
0.16%
0.08%
0.12%
0.32%
0.12%
3.93%
3.97%
0.91%
0.36%
0.67%
4.60%
0.40%
0.08%
32.01%
6.98%
1.63%
4.01%
3.05%
2.10%
1.86%
0.44%
0.36%
0.16%
16.94%
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35 CC-COLLAR
CE-ELBOW
CSP-SCREWEDPIPING
CTC-TUBINGCOLLAR
CTE-TUBINGELB
CT-TEE
CTT-TUBEFITTINGTEE
CTU-TUBINGUNION
CUB-UNIONWSPBLIND
CU-UNION
F-FLANGE
FO-ORIFICEPLATEFLG
FSP-FLGSCREWPIPE
GG-GAGEGLASS
KC2-CENTRIFUGALCOMP
KC-CENTRIFUGALCOMP
KDHP-DOGHOUSEPLATE
KR4-RECIPCOMPRESSOR
KR-RECIPCOMPRESS
KUV-UNLOADERVALVE
KUV-UNLOADERVLVFLG
KUV-UNLOADERVLVOTH
PC2-CENTRIFUGALPMP2
PC-CENTRIFUGALPUMP
RC-PRESSRELCLOSED
RO-PRESSRELIEFOPEN
TM-TRANSMITTER
VC-CONTROLVALVE
VC-CONTROLVLVFLG
VC-CONTROLVLVOTH
VG-GATEVALVE
VG-GATEVLVFLG
VG-GATEVLVOTH
VL-BELLOWSVALVE
VL-BELLOWSVLVFLG
VN-NEEDLEVALVE
VN-NEEDLEVLVFLG
VN-NEEDLEVLVOTH
VX-CHECKVALVE
VX-CHECKVLVFLG
AllFlanges
PercentageofTotalLeaks>100PPM
Gate Valves:
32 % of the total
leak
Source - EPA federal / state / regional air districts enhanced LDAR program, Bill Ross, SCOPV spring 2010

8. Need for Fugitive Emissions
Standards for Valves…
8

9. FE Standards in the Industry
9

10. Preferred Fugitive
Emissions Standards
10

11. Variation in Type Test Standards
Type test
standards
Test Medium
Helium -196°C to 538°C
Methane -29°C to 260°C
Test Method
Sniffing
He Mass
Spectrometer
ppm
Atm.cc/sec
Organic Vapor
Analyzer
ppm
Vacuum
He Mass
Spectrometer
Atm.cc/sec
Test Parameters
Leakage
ppm 50 , 100, 500
Tightness Class Class A, B,C
Mechanical
Cycles
200 to 2500
Thermal Cycles 2 to 5
Gland
Adjustment
1 to 3
11

12. PARAMETERS
Method
Medium
Units
Leakage
Mechanical
Thermal
Max temp
Max SSA
ISO 15848
2nd Ed
Vacuum/Sniffing
Helium/Methane
Atm.cc/sec
Class A/B/C
205 to 2500
2 to 4
User defined
1 to 3
API 622 2nd
Ed
Sniffing
Methane
ppm
<500
1510
5
500°F (260°C)
User defined
API 624 1st
Ed
Sniffing
Methane
ppm
<100
310
3
500°F (260°C)
0
API 641 1st
Ed
Sniffing
Methane
ppm
<100
610
3
500°F (260°C)
0
Comparison among FE Standards…
12

13. Leakage Correlation for a
4” Class 300 Gate Valve
13
Leakage Class (1” Stem dia) Correlation Remarks
~ Leak volume that will fill a Golf ball
in a year
~ Leak volume that will fill a Tennis
ball in a year
~ Leak volume that will fill a Soccer
ball in 4 years or 10 tennis balls in a
year
~ Leak volume that will fill 25 Soccer
balls in a year or 1000 tennis balls in
a year

14. Milestones in L&T’s FE journey
– 2000 to till date
Year FE test procedure Test conducted @ Result
2000-02
Clean air act
(EPA Method-21)
LTV R&D Pass
2003
Clean air act
(EPA Method-21)
Yarmouth labs, US Pass
2007-08 API 622 LTV R&D Pass
2008 API 622 Yarmouth labs, US Pass
2010 ISO 15848 Cetim, France Pass
2011 TA-Luft LTV R&D Pass
2010-12 ISO 15848 LTV R&D Pass
2013-15 ISO 15848 LTV R&D Pass
2014-16 API 624 Yarmouth labs, US Pass
2016-18 API 641 LTV R&D Pass
14

15. API 624 FE testing at
Yarmouth lab, USA: 2014-16
15
12” Class 300 Gate being
tested at Yarmouth
20” Class 300 Gate being
tested at Yarmouth

16. Large Size Low E Valves
Designed & Manufactured
Valve size: 72” Class 150 Gate Valve
Valve Weight: 26 Tonnes
ISO 15848 Class B Emissions
Project : Reliance Industries J3
Valve size: 24” Class 300 Gate Valve
Valve Height: 4.1 Metres
ISO 15848 Class A Emissions
Jubail Export Refinery Project
16

17. Low FE Valves Range
Valve Type
Tightness
Class
Endurance
Class
Sizes
Pressure
Classes
Temperature
Gate, Globe
& Check
Class AH, BH,
CH
CO2
Entire range
150 to 2500
-46 to 400
Pressure
Seal Gate,
Globe &
Check
Class BH
CO2
2” to 36”
900 to 2500
-46 to 400
TMBV
Class AH, BH
CO2
Entire range
150 to 2500
RT to 200
TOBV
Class AH, BH
CO2
4” to 42”
150 to 600
RT to 400
17

18. Standard Requirements on
Stem and Stuffing-box Surface Finish
18

19. Surface Roughness
Roughness
values Ra
Roughness
values Ra
Roughness
API standards
recommendation
micrometer microinch
Grade
Numbers
API 600 13th Ed
6.3 250 N9
4.5 175 -- Stuffing box (Maximum)
3.2 125 N8
1.6 63 N7
0.8 32 N6 Stem (Maximum)
0.4 16 N5
0.2 8 N4
0.1 4 N3
0.05 2 N2
Smooth

20. 16
16
8
16
16
16
16
16
32
32
32
32
32
32
32
32
24
32
32
32
16
32
32
API 600, 13th Ed
API 623, 1st Ed
API 603, 8th Ed/9th Ed (Draft)
API 602, 10th Ed
API 622, 2nd Ed/3rd Ed (Draft)
API 621, 3rd Ed
API 621, 4th Ed (Draft)
MSS SP-120, 2011
A
B
C
D
E
AAA
BBB
StandardsPackingMfr
End-
user
Max Min
Finish values shown in Microinches
Stem Finish Standards,
Manufacturers, End-users

21. 32
100
75
32
75
175
175
175
175
125
175
175
125
125
63
125
125
125
125
125
125
API 600, 13th Ed
API 623, 1st Ed
API 603, 8th Ed
API 603, 9th Ed (draft)
API 602, 10th Ed
API 622, 2nd Ed/3rd Ed (Draft)
API 621, 3rd Ed
MSS SP-120, 2011
A
B
C
D
E
F
AAA
BBB
StandardsPackingMfr
End-
user
Max Min
Finish values shown in Microinches
Stuffing-box Finish Standards,
Manufacturers, End-users

22. 22
Test Results on Various
Stem Finish and Stuffing Box

23. Test Valves Identified for Analysis
Valve Size Class Rating Material No of tests
done
4” (DN 100) 300 ASTM A216 Gr. WCB 6
4” (DN 100) 900 ASTM A216 Gr. WCB 3
4” (DN 100) 1500 ASTM A216 Gr. WCB 3
8” (DN 200) 600 ASTM A352 Gr. LCC 3
12” (DN 300) 150 ASTM A351 Gr. CF8M 3
16” (DN 400) 900 ASTM A216 Gr. WCB 2
20”(DN 500) 300 ASTM A216 Gr. WCB 2
23

24. Stem Finish Vs Leakage Comparison Chart
Supplier X (Braided & Die-moulded Combination Packing)
24
Stem finish
Stuffing box
finish
Leakage, ppmv
Test result
Average Maximum Minimum
4 µinch
(0.1 µm)
63 µinch
(1.6 µm)
6.5 11 3.6 Pass
32 µinch
(0.8 µm)
63 µinch
(1.6 µm)
33.3 150 2.7 Fail

25. Stem Finish Vs Leakage Comparison Chart
Supplier Y (Braided & Die-moulded Combination Packing)
25
Stem finish
Stuffing box
finish
Leakage, ppmv
Test result
Average Maximum Minimum
4 µinch
(0.1 µm)
63 µinch
(1.6 µm)
19.8 65 3.4 Pass
32 µinch
(0.8 µm)
64 µinch
(1.6 µm)
70.1 380 4.3 Fail

26. Stem Finish Vs Leakage Comparison Chart
Supplier Z (Fully Braided Packing)
26
Stem finish
Stuffing box
finish
Leakage, ppmv
Test result
Average Maximum Minimum
4 µinch
(0.1 µm)
63 µinch
(1.6 µm)
8 17 2 Pass
32 µinch
(0.8 µm)
64 µinch
(1.6 µm)
6 21 1 Pass

27. Stuffing Box Finish Vs
Leakage Comparison Chart
27
Stuffing box
finish
Leakage, ppmv
Test result
Average Maximum Minimum
16 µinch
(0.4 µm)
7 13 4 Pass
63 µinch
(1.6 µm)
9 15 4 Pass

28. API 624 Results
L&T Gate Valves
28
3
20
7
14
6 85
25
12 15
8 11
100 ppmv
4" Class
300
12" Class
300
20" Class
300
12" Class
600
4" Class
900
4" Class
1500
Die-formed+ Braided
packing Leakage (ppmv)
Average Static
Average Dynamic
Maximum API 624
6
1
10 8 11 11
3 6
13 10 8 9
100 ppmv
4" Class
300
12" Class
300
20" Class
300
12" Class
600
4" Class
900
4" Class
1500
Fully braided packing
Leakage (ppmv)
Average Static
Average Dynamic
Maximum API 624
Static and Dynamic leakage results < 50 ppmv

29. Conclusion…
Braided & Die-moulded Combination Packing
• From the test results, Stem finish 4 µinch (0.1µm) play a major role in
Braided & Die-moulded Combination Packing
• Smoother stem finish 4 µinch (0.1µm) gives a better Fugitive emission
results on Braided & Die-moulded Combination Packing
• The valve operating torque was ~12% higher with Braided & Die-moulded
Packing compared to fully braided packing
Fully Braided Packing
• For Braided packing, Stem finish does not have any impact on the Fugitive
Emission test
Stuffing Box
• Stuffing box finish does not have any impact on the Fugitive Emission test
29

30. Thank You
30