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

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 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

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

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

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

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

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 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

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

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

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

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

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.

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

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