62 SEALING SENSE

API 622: Valve Packing for Fugitive Emissions

By Mark Freeman
FSA Member, EGC Enterprises, Inc.

T
he American Petroleum Institute
(API) has developed two commonly
used standards designed
specifically for the petroleum industry.
They include API 622 “Type Testing
of Process Valve Packing for Fugitive
Emissions,” and API 624 “Type Testing
of Rising Stem Valves Equipped with
Graphite Packing for Fugitive Emissions.”
API 622 and API 624 may be specified
by an end-user. Valve OEMs must use
API 622-approved packing for any valve
on test for API 624. Image 1 (left). Testing fixture
Image 2 (right). Thermo toxic vapor analyzer (Image courtesy of Yarmouth Research)
Fugitive Emissions Test Standards
Since the introduction of the U.S. Clean and repair (LDAR) protocols monthly. a variety of packing sets from multiple
Air Act in 1963, the U.S. Environmental The EPA monitors leak detection using manufacturers can be evaluated under
Protection Agency (EPA), as well as “sniffing” technology. Although alternate the same conditions.
individual states, have set increasingly test methods are being used, fines The third edition of API 622 restricts
stringent restrictions regulating fugitive for falling out of compliance can cost leakage of the packing set to a maximum
emissions from industrial facilities. some companies millions. So, reducing of 100 parts per million volumetric
Fugitive emissions are any chemical fugitive emissions not only protects the (ppmv), while eliminating the single
in a physical form that can unknowingly environment but also saves money for previously allowed gland bolt adjustment.
leak from an installation. Valves account industrial facilities. This edition also adds the requirement
for more than 51 percent of all fugitive Recently, there has been a focus on of an 1/8-inch packing sample test,
emissions, including greenhouse gas. replacing the “repair” in LDAR with a which has been problematic in valve type
Eighty percent of these emissions come more proactive, preventative approach testing, alongside the 1/4-inch packing,
from the valve stem—representing that focuses on valve design and low which has been used exclusively in all
more than 300,000 tons annually. emissions (low E) performance at the earlier revisions.
It is generally estimated that a high manufacturing level. Currently, API 622 is a performance
proportion of emissions come from test. It runs a span of 1,510 mechanical
hydrocarbon gasses such as methane. API 622 cycles (from open to close) at 600
The consequences of these losses are The first in a series of embedded low E pounds per square inch gauge (psig)
far-reaching. They include the loss valve and packing standards is API 622, operating pressure over five thermal
of product in terms of the cost of which was revised for the third time. This cycles. Measurements of test gas leakage
fugitive emissions, cleanup costs, loss is a test standard for the packing itself. (methane) are taken periodically
of production time and labor costs to It uses a standardized test fixture and throughout the test.
repair leaks. eliminates all the variable conditions During the thermal cycling test,
Plants handling fugitive emissions are inherent in each valve. By using a test the fixture operates at ambient
expected to implement leak detection fixture and a specified set of conditions, temperature for 150 cycles. At that

M a y 20 1 9 | Pumps & Sy stem s

Table 1. stuffing box dimensions and tolerances (Image courtesy of EGC Enterprises)
Item 1/8-inch Packing Fixture 1/4-inch Packing Fixture
Stem diameter 11.05 mm to 11.1 mm (0.4355 in. to 0.4375 in.) 25.2 to 25.4 mm (0.992 in. to1.0 in.)
Stem straightness Max. 0.04 mm per 305 mm (0.0016 in. per 12 in.) Max. 0.04 mm per 305 mm (0.0016 in. per 12 in.)
Stem cylindricity 0.04 mm max. (0.0016 in. max.) 0.04 mm max. (0.0016 in. max.)
Stem surface finish 0.40 μm Ra to 0.80 μm Ra (16 μ-in. Ra to 32 μ-in. Ra) 0.40 μm Ra to 0.80 μm Ra (16 μ-in. Ra to 32 μ-in. Ra)
Stuffing box diameter 17.46 mm + 0.06 mm or – 0.0 mm 38.1 mm + 0.25 mm or – 0.0 mm
(0.6875 in. to 0.6900 in.) (1.5 in. to 1.510 in.)
Stuffing box depth 19.05 mm ± 1.5748 mm (0.75 in. ± 0.062 in.) 44.5 mm ± 1.5748 mm (1.75 in. ± 0.062 in.)
Stuffing box surface 3.20 μm Ra + 1.25 μm Ra or – 0.625 μm 3.20 μm Ra + 1.25 μm Ra or – 0.625 μm
finish (125 μ-in. Ra + 50 μ-in. Ra or –25 μ- in.) (125 μ-in. Ra + 50 μ-in. Ra or –25 μ- in.)
Gland bottom machined
0.15 mm (0.006 in.) max. 0.15 mm (0.006 in.) max.
flat
Gland to stuffing box
0. 63 mm to 0.190 mm (0.0025 in. to 0.0075 in.) 0.13 mm to 0.38 mm (0.005 in. to 0.015 in.)
diametrical clearance
Stem to gland (flange)
0.254 mm to 0.381 mm (0.010 in. to 0.015 in.) 0.5 mm to 0.8 mm (0.020 in. to 0.030 in.)
diametrical clearance
Gland stud diameter 3/8 in. - 16 UNC (2 pieces) 5/8 in. - 11 UNC (2 pieces)

point, the temperature is increased to test is to measure the low E capability of No stem seal adjustments are allowed.
500 F, running another 150 cycles. This a valve over an accelerated lifecycle. API If at any point the leakage exceeds 100
sequence repeats four additional times, 624 is a valve-type test meant to evaluate ppmv, the test is considered a failure.
and the final stage of the test runs for the total performance of the valve itself The API taskforce is working on a new
10 cycles at ambient temperature. and not the packing alone. revision of API 624 and has expanded its
The test fixture is designed to resemble The packing used in an API 624 tested line of valve standards by adding API
a 4-inch, 300-pound gate valve, using a valve should be previously tested to 641 for emission-type testing of quarter-
1/4-inch cross-section packing sample measure up to API 622 requirements. turn valves.
and a 4-inch stem stroke (or the distance All the variables within a given valve
traveled from fully open to fully closed, design are being tested in API 624, while Next Month: Sealing High-Speed
see Image 1). Stem diameter is 1 inch and the packing has been proven to be, at Shafts in Turbo-Machines
box diameter is 1.5 inches for a 1/4-inch least theoretically, suitable for use in a
packing cross-section size. low E valve. We invite your
This test fixture is detailed within The test runs a span of 310 mechanical suggestions for article
topics as well as questions
the test standard so that every test, cycles at 600 psig operating pressure on sealing issues so we
independent of location, can be over three thermal cycles. All the while, can better respond to the
compared and evaluated. Leakage of periodic leakage measurements are needs of the industry. Please direct your suggestions and
up to 100 ppmv is permitted. Leakage taken of the test gas, which is specified questions to [email protected].
measurements are taken using an organic as methane.
vapor analyzer (Image 2) to measure During the thermal cycles, the valve
hydrocarbons and volatile organic will run at ambient temperature for 50
compounds (VOCs). The test no longer cycles. The temperature is increased to
Mark Freeman is the
allows one adjustment of the gland bolts 500 F, and the valve is cycled another
marketing director for
if the packing set began to leak. 50 times.
EGC Enterprises, Inc.
Finally, the valve is returned to
For more than 25 years,
API 624 ambient temperature for a run of 10
he was CEO of Mark
This is a test for the valve itself, including cycles. Allowable leakage during this test
Freeman Advertising.
the stem packing. The intention of this is 100 ppmv at the stem and bonnet seal.

p u m p s a n d s y s t e m s . c o m | M ay 2019