Gland Packing of Control Valves

Presented by: Muhammad Asim

CONTENTS

Introduction to Packing
Types of Packing
Packing Material Consideration
Packing Configurations
Packing Procedure
Common Mistakes in Packing
Packing Configuration of Critical Valves
Incidents of gland packing failures and its consequences

What is Gland Packing?

Any soft material encased in bonnet or body
used to seal a valve stem or shaft is called
Packing.
Packing held in place by a Packing Follower
with compression supplied by Gland/Packing
Flange.
Packing follower is a metallic ring used to retain
packing inside bonnet or body and to compress
the packing in uniform manner.
Gland flange is a rectangular metallic block
connected to valve body through bolting.
When bolting is tightened the gland flange
through packing follower- transfers an axial load
to the packing, compressing the packing until a
seal is created against stem and bonnet bore.
The configuration of packing, packing follower,
gland flange, studs is called PACKING BOX.

What is Lantern ring?

A lantern ring is an annular ring with channels for
the passage of water that is inserted between the
gland packing. Fluid is fed from an external pipe
to the lantern ring for lubrication OR cooling of
the stem/packings.
It is used in applications where a number of
packings are there and it would be difficult for the
intermediate packing to get fluid for lubrication.
It is also used where the fluid to be sealed is
contaminated with abrasives or is corrosive and a
clean fluid is required for lubrication.
While installation it is crucial that the holes in the
lantern ring meet or are aligned with the holes in
the pipes.
It is very important to inspect and align the
lantern ring during each overhaul of the valve.

Position of Lantern Ring

Loading of Packing Rings

Depending on material packings

produce a unique deformation
when compression is applied.
Applied axial load can result in
wide range of radial load.
Ideally, when axial load is
applied, radial load should be
greatest in middle of packing set
where maximum seal occurs.

Loading of Packing Rings

Packing Types

Packing Types: Jam Style

Packing is loaded by compressive force
exerted by packing follower. Only elasticity
in this system resides in the packing
material itself. This is called stationary or
jam style packing. Over time packing
material wears, the packing follower must
be re-compressed by carefully tightening
the packing nuts.
Excessive torque will result in high valve
stem friction and premature packing failure.
Proper remedy for a packing assembly that
leaks despite having been properly torque is
replacement, not further tightening.

Packing Types: Live Loading

A metal spring is inserted in packing
assembly, so that the elasticity of the
springs helps to maintain an appropriate
amount of packing stress as the packing
material wears and ages. This is called live
loading.
Two types of live loading;
a. A coil spring inside the bonnet used to
live-load the pacing.
b. Set of spring-steel washers known as
Belleville springs installed between
packing flange and follower. These
washers always stacked in opposite
pairs as shown in picture.

Packing Types: Live Loading

Packing lubricators

In packing applications requiring

external lubrication, a stem
packing lubricator may be
connected to the lubrication port
on the bonnet. This device uses
a long, threaded bolt as a piston
to push a quantity grease into
the packing assembly

Packing Material Considerations

Packing Material: PTFE

PTFE is common and inexpensive packing material.
Generally used in V-rings.
With combination of PTFE elasticity and and the
pressure energized design of v-rings, little compression
is needed to create long lasting seal.
PTFE provides very little friction. Therefore allows
smooth stroking and minimum breakout force, necessary
to begin valve lift.
PTFE is inert to many process fluids.
PTFE can be used up to maximum 232 deg C
temperature.

Packing Material: PTFE

Major disadvantage of PTFE is its limited temperature
range.
Because its thermal expansion is 10 times to thermal
expansion of steel, PTFE is especially vulnerable to
thermal cycling, which can result in packing loss and
shorter life. As PTFE is heated by the process, it
expands throughout all available spaces, which may lead
to extrusion. As the temp drops, the packing returns to
its original volume minus the amount lost to extrusion.
Bcz of this loss, less force is exerted against stem or
bonnet wall and consequently leakage occur.

Packing Material: PTFE

Another disadvantage of PTFE is its tendency to
consolidate over a period of time known as cold flow. It
occurs when packing is compressed several times or if live
loading is used. To prevent it, a backing or anti-extrusion
ring can be installed that will slow the process. A backing
ring is a close tolerance ring made from a harder less
pliable material and is inserted at top of packing to transfer
the axial force from gland flange to packing. In most cases
backing rings are installed at both ends of PTFE packing
and provide an exact fit between the ring and stem as well
as packing box wall. This exact fit is critical to preventing
the cold flow from extruding past the back up ring.
Filled PTFE is similar to PTFE although it includes some
glass content to provide more rigid V-ring that is less likely
to consolidate.

Packing Material: Graphite

Graphite is an expensive but high temp alternate to
PTFE for packing.
Graphite can be produced in die formed rings and
braided rings.
Die formed rings are produced from graphite ribbon,
which is wound and then compressed in a die according
to specified pressure. This pressure to form the rings is
less than the force required to compress the rings to seal
the packing box.
Braided graphite is produced by winding small strands of
graphite together which makes it quite pliable as
compared to die formed rings. When used as sealing
packing, it forms so well to the stem that the resulting
stem friction impedes free movement of the stem.

Packing Material: Graphite

Because of this problem, braided packing is used as an
anti-extrusion ring on both sides of the die formed rings.
However, this may cause a problem when higher
compression is need, since braided graphite has the
tendency to grab the stem and not transfer the load to
die formed rings. Hence higher friction results from
braided packing, yet leakage may occur because
insufficient load is reaching the primary seal which is the
die formed rings.

Packing Material: Graphite

Graphite packing offers number of advantages. Overall
graphite remains stable over a wide range of thermal
cycling, bcz its expansion is nearly equal to steel, it does
not extrude or loose seal in thermal cycles.
Chief drawback of graphite is that when fully
compressed to provide effective seal, it has a tendency
to stick to the stem resulting in jerky valve motion or
premature wear of moving parts. This phenomena is
more sever in rotary valves as compared to linear
valves.
Another major problem with graphite is that it is
extremely fragile and can be broken or crushed when
over compressed or over tightened. Using wrenches to
apply recommended torque is mandatory when installing
graphite packing.

Packing Material: Graphite

Graphite packing also has the unfortunate property of
permitting galvanic corrosion between the stem and
bonnet metals due to its electrical conductivity. Sacrificial
zinc washers are sometimes added to graphic packing
assemblies to help mitigate this corrosion, but this only
postpones rather than prevents corrosive damage to the
stem.
The packing manufacturer should be consulted to
determine whether the valve should be removed during
hydro testing. Graphite packing will corrode the stem if
left wet.
Graphite is fire safe which is important where fire
migration is a concern.

PACKING CONFIGURATIONS

Packing Configuration, Single

This is an economical seal for many applications. Single
packing consists of a stack of packing at the top of the
packing box supported by either a spring or gland
follower. Spring packing can be accomplished by having
the packing follower drawn against the bonnet to
compress the spring.
PTFE: V-rings and braided packings can be used in
single packing configuration.
Graphite: Combination of square and braided packing is
used in single configuration.
Picture on next slide shows a single packing
arrangement using V-rings.

Single Packing Arrangement

Single packing arrangement using PTFE V-rings

 Double packing arrangements provide a more rugged

seal than single arrangements and generally have
packing above and below the lubricating/ lantern ring
connection.
PTFE: V-rings and braided packings can be used in
double packing configuration.
Graphite: Combination of square and braided packing
can be used in double configuration with lantern ring for
lubrication purpose. Lubrication keeps the graphite
packing soft and pliable while providing smooth valve
travel.
Double packings are also used for vacuum and pressure
services.

Double packing arrangement using PTFE V-rings

Graphite packing is not as

resilient as PTFE packing
and any lateral movement of
the stem will enlarge the
packing bore, leading to
leakage. To prevent packing
damage and subsequent
leakage,
carbon
guide
bushings are located above
and below the packing rings
to provide stem guiding. The
guide bushings are made of a
nonmetallic
material
to
prevent scratching the stem.

 Packing consolidation is a reduction in packing volume due

to Wear, Cold Flow, Plastic Deformation and Extrusion.
When packing is loaded to its proper stress level it has a
tendency to cold flow and will extrude between the stem
and the follower. PTFE has an expansion rate roughly ten
times that of carbon steel. As the temp rises, packing tries
to expand in the fixed volume of the stuffing box, extrusion
will occur. This material loss due to extrusion will relieve the
axial stress, which relaxes the radial stress and results in a
loss of seal.
In most cases when consolidation occurs, the packing box
will begin to leak and the gland flange bolting must be
tightened further to seal the leakage.

 By virtue of its close proximity to process, packing

material can be affected by the process temp and press.
As the Temperature increases, softer packing material
will become more fluid and are more apt to extrude out
of the packing box.
High pressure can also cause extrusions.
PTFE packing can be used up to 230 Deg C. For higher
temperature, graphite packing is used.
Valve OEM manual must be consulted for recommended
packing material at specific temperature and pressure.

 Clean and inspect nut and bolts. The nut should be able
to smoothly travel the length of bolt. Test by finger
tightening.
Always use hardened flat washers under gland nuts to
evenly distribute the torque to gland flange.
Ensure packing gland follower can be inserted freely into
the stuffing box without interference.
Make sure packing follower is seated evenly against the
packing.
Measure the distance between gland flange and stuffing
box face to ensure evenness.
Readjust gland nuts after the valve has been actuated a
minimum of five times with the valve in the closed stroke
position.

1. Trueness of the shaft. A shaft that is bent would eat the

gland packings prematurely and there nothing you can do
except change the shaft. You must make it a point to
check the trueness of the shaft during each overhaul
using a dial gauge.
2. Concentricity of the shaft with the stuffing box bore.
The shaft might be true but if not aligned properly would
again destroy the gland packings in no time.
3. Surface roughness of the shaft. If the shaft or the
sleeve is pitted or unevenly worn it would again damage
the gland packings very fast.

PROCEDURE FOR NEW PACKING

Videos of Packing Installation

Installation of Braided Packing

Installation of V-ring Packing

Installation of Graphite Packing

Common Mistakes in Gland Packing

Common Mistakes in Gland Packing

Uneven tightening of gland pusher
Gland pusher at least 2-3 mm inside stuffing box
Do not use reinforced braided packing (doori) on hydrogen
service
Short bolting of gland nuts
Lantern ring position

Packing configuration of critical valves

01-LRC-1V
01-LRC-2V
05-HIC-1V
05-LIC-5VA/B

 Braided packing provided

in twin configuration.
Lower packing has four
rings while upper packing
has 08 rings.
Lantern ring is provided for
circulation of clean water
which takes away any
leaking fluid from lower
packing. Flushing water
will also serve as cooling
media for valve stem.
Bushing is provided for
alignment of valve stem.

 V-rings provided in twin

configuration
(06+01+01+03).
Lantern ring is provided for
circulation of clean water
which takes away any
leaking fluid from lower
packings. Flushing water will
also serve as cooling media
for valve stem.

 PTFE V-rings provided on both sides of Butterfly body.

 V-rings
provided
in
twin
configuration (05+05).
Spring is provided in between
circulation of clean water which
takes away any leaking fluid from
lower packings. Flushing water
will also serve as cooling media
for valve stem.
Mettalic
Anti-extrusion
rings
provided (Item # 17a, 23 in
picture) to prevent extrusion of
packing rings.
05-FRC-3V

 V-rings
provided
in
twin
configuration (05 + 05 reverse).
Spring is provided in between
circulation of clean water which
takes away any leaking fluid
from lower packings. Flushing
water will also serve as cooling
media for valve stem.
Mettalic Anti-extrusion rings
provided (Item # 17a, 23 in
picture) to prevent extrusion of
packing rings.

05-LIC-5A/B

INCIDENTS OF PACKING
FAILURE

 Packing of 05-HIC-1V was failed in plant

startup in 2012 at Plant-I.
Plant startup was halted and glands were
repacked in field.
Valve was attended in workshop and its stem
and gland packing were replaced.
Cause: Gland follower outside stuffing box
due to installation of additional braided
packing (Doori) in addition to PTFE V-rings to
create extra margin for future tightening in
field..

Incident Report

On October 19, 2014 at 1740 hrs, excessive Synthesis

Gas leakage with a jet of approximately 8-10 ft was
observed from Ammonia reactor, R-501 inlet valve, 05HIC-1V east side gland packing (Non-actuator side).
In May, 2014 during startup of the plant, the leakage
from gland packing of 05-HIC-1V was observed (hand
felt). The leakage was arrested at that time by tightening
the gland packing. Based on May 2014 leakage
history/incident, the gland packing was attended during
turnaround 2014, by adding packing rings and tightening
of packing.

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