Packing Newsletter October 07

Packing newsletter October 2007 Ron Frisard Global Training

Goals of the newsletter
Simple way to communicate information
Talk about packing news and information
“ Sharpen the Saw”
Three main areas
1) Highlight a piece of information on packing
(Fugitive emissions article)
2) Highlight a Chesterton packing product
Chesterton Flange Springs
3) Highlight a packing case history
Sugar Mill application

Article on Fugitive Emissions
Article by P.J. Lakhapate
Chemical Engineer from Bechtel
Focuses on fugitive emissions
What are they?
Why important?
What Factors?

Article on Fugitive Emissions -continued
Costs from Customer Perspective
Visible cost
- Loss of material
Invisible costs
- Labor to repair leaks
- Material to repair leak
- Wasted energy
- Low plant efficiency
- Environmental clean up
- Environmental fines
- Lost sale due to poor image
- Claims for personal injury
Sources of fugitive emissions?
Atmospheric tanks with/without breather valve
Tank lids
Seals of rotary equipment e.g. Pump Blower, Compressor, Turbine,
Agitator
Flange joints
Leakage through vents & drains.
Valve stem seals
Sample points
Distribution of fugitive emissions: Valves - 60% Relief Valves - 15% Tanks - 10% Rotary Equipment - 10% Flanges - 5% Help in detailing ROI Where to look

Article on Fugitive Emissions -continued
Bolted Flanged Connections:
The factors affecting the leakages are
a) Non parallel flanges
b) Non smooth surfaces
c) Surface waviness
d) Quality of gasket
e) Type of gasket (Non metallic, Semi -metallic, Metallic)
f) Form of gasket (Plane Sheet, Rectangular, Spiral wound)
g) Type of joint involved ( flat, tongue & groove)
h) Process parameters (Pressure, Temperature)
i) Fluid handled
j) No. of Bolts
k) Installation Procedure (placement of gasket, tightening of bolts)
l) Maintenance
A study conducted by the Pressure Vessel Research Council (PVRC) in the USA indicated that most flange joint failures resulting in leaks were due to a) Improper installation - 26% b) Flange Damage - 25% c) Gasket - 22% d) Loose Bolts - 15% e) Flange Misalignment - 12% Cheterton "know how" and product can help

How to find article
Website:
http://www.scienceinafrica.co.za/2006/april/fugitiveemissions.htm
(or http://tinyurl.com/2tdotg)

Chesterton Valve packing friction paper
Chesterton completed a two year research paper on valve packing friction earlier this year
The paper focused on capturing the effects of thermal cycling of packing friction for various Chesterton packings
145 page white paper explaining all testing and results
It can be downloaded at:
http://tinyurl.com/2o9w86

Chesterton Flange Springs
Chesterton’s flange live loading is intended to compensate for thermal cycling effects by storing elastic energy
Stored elastic energy delays the loss of bolt stretch

Bolt Stretch Comparison ANSI 24” 150lb Flange, 1-1/4”Bolt, Length 6.750” Plain bolt 0.0078 Inch Stretch bolt 0.0102 Inch 0.0417 Inch 0.0291 Inch 0.0240 Inch 0.0208 Inch 5500 5505H-30K 5505H-45K 5505H-60K Assembly Force 45,411 Lbs 2.6X 3X 3.7X 5.3X Values Below for only one side of Springs Double if springs on both sides

Product highlight: 5500/5505H Flange springs
5500 Flange springs
Made of 17-7 pH stainless steel
Maximum flange temperature of 572°F (302°C)
2 springs per side for B7 bolting
Come in one load range
Can be made of special materials
5505H Flange springs
Made of High strength Chromium based Steel
Maximum flange temperature of 1100°F (595°C)
1 springs per side
Come in three load ranges: 30K,45K, and 60K

Case history –Sugar Mill
Application: Raw juice pump
Problem:
Pump Leakage (3-5 gallons per minute)
Try to reduce leakage / burn up packing
Maintenance problems (constantly adjusting / repacking) ~ 50% uptime

Case history –Sugar Mill
Solution:
1400* with Rotary Live loading
No product leakage
95% uptime
Every gallon saved is equal to 1 Lb of sugar saved!
1400* saved 289 tons of sugar during one season (134 days)
Plant needed to change train schedule because silo’s filled up sooner then before
*This was before 1400R was released and improved

Any questions…
If you have any questions or comments about this on-line newsletter please contact
[email_address]
Also please email any case histories you might want to share.

Packing Newsletter Index
August
Info: heat rate improvements paper
Product: 5800T
Case History: Coke plant / CMS-2000
September
Info: Bolting website
Product: 184/185
Case History: Brine pump / Superset
October
Info: Fugitive emissions leakage paper
Product: Flange Springs
Case History: Sugar Mills/1400

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Packing Newsletter October 07

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