original 51848 jw valve brochure 24pp updatenew
TRANSCRIPT
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Improving valve sealing performance& emissions control
High Performance Sealing Technology
Issue 2
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Respected reputation
For further details, call your local contact shown on rear cover or email [email protected]
Over a century o experience
James Walker has been in the businesso luid sealing and control since thecompanys ounding over 125 yearsago. From our earliest products andthroughout our history the companyhas developed sealing solutions andcomponents in parallel with advancesin valve technology. As a result we haveamassed specialised knowledge oapplications across a very broad range
o industries.
Driving advances inperormance
From marine transport and aerospaceto nuclear energy, renewables, oil andgas, our experience drives innovations inmaterials and sealing technology that helpacilitate production and perormanceadvances. Across a broad range oapplications James Walker products and
materials oer class-leading capabilitiesand are considered a perormancebenchmark in many industry sectors.
CONTENTS
Respected reputation 2
Global presence local support 3
Cost-eective solutions 4
Depth o experience 5
Fugitive emissions 6-7
Elastomer products 8-9
Compression packings 10-11
Gaskets 12-13
Valve seating 14-15
PTFE Chevron & KVSP 16
Spring energised PTFE lip seals 17
Metallic bellows 18
Specialised metal components 19
Tension control bolting 20-21
Services 22
Technical guides & data sheets 23
A respected reputation
built on a history of
innovation and proven
performance
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James Walker & Co
Advanced sealing materialsdevelopment, manufacture and
applications engineering
James WalkerKeaflex
Design andmanufacture of complex,
precision moulded
elastomer products
James WalkerDevol
High performanceengineering in
advanced thermoplasticmaterials
Globalexpertise
James WalkerRotaBolt
Assured bolted joint integritythrough bolting installation
and tension controlmanagement systems
James WalkerTownson
Custom designand manufactureof bellows and
expansion joints
James WalkerMoorflex
Precision machining ofcomplex components in
metals and exotic alloys
Global presence local support
For further details, call your local contact shown on rear cover or email [email protected] 3
Bespoke solutions
Bespoke doesnt necessarily meanexpensive. At James Walker our aim isto create the most cost-eective solutionand we ocus careully on optimisingthe lietime cost o ownership or ourcustomers.
We carry a global reputation or solvingsealing problems. Backed by testing andmanuacturing to world-class standardsJames Walker brings practical expertiseand leading edge technology to thecustom-design o optimum solutions thatmatch our customers exact operationalrequirements.
Worldwide distribution
Our role as a global supplier demands aninternational manuacturing baseplus highly eicient sales and distributionoperations. We have a worldwide amilyo companies with over 50 production,engineering, distribution and customersupport sites spread across Europe,
Australasia, Asia Paciic, Arica and theAmericas.
At the local level, a close-knit networko James Walker companies and oicialdistributors works in close partnership withcustomers in well over 100 countries.
Our focus is
on providing
cost-effective
operational solutions
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For further details, call your local contact shown on rear cover or email [email protected]
Cost-effective solutions
Testing capabilities
Environmental chambers capable oreplicating conditions rom -70C to+130C
Rapid gas decompression rigs amongst the most advanced in theworld
Steam skid or testing seal longevityunder harsh Sterilisation in Place (SIP)
steam cycle cleaning
Multiple rotary and reciprocating testrigs with a variety o shat sizes andspeeds rom gentle oscillation to inexcess o 6,000 revolutions per minute
Chemical type-approval testing whichallows customers the opportunityor third party-witnessed testing oelastomers and polymers in theiranticipated chemical environment
With in-house materials compounding
we also hold complete control over batchproduction essential during criticaltesting and materials assessment.
Proving perormance
Working in close co-operation withcustomers, industry bodies and academicinstitutions, our acilities provide some o
the most advanced test regimes outsideo actual operational application. Thisgives our customers the conidence thatJames Walker products have been ullytested to meet the required applicationconditions.
With our broad range o engineeringresources and expertise we design andbuild custom test-rigs or many o theprojects we undertake. In addition, andcentral to our research and developmentprogrammes, the James WalkerTechnology Centre houses the core o
our world-class test acilities.
Driving development
Our position as a technology leader, incombination with the vast experienceo our applications engineering andmaterials science teams, helps us toidentiy and supply the most appropriateand competitive solution or eachindividual customers requirement.
We run a structured developmentprogramme or each o the industrial
markets served by our business. Workingin partnership with customers we identiythe current and uture needs to beaddressed to improve key perormanceparameters such as cost eectiveness,longevity, saety and environmental care.
Delivering quality
Quality design, quality manuacture andquality service are paramount throughoutour worldwide operations. We start withthe best raw materials and use advancedmanuacturing techniques with strictquality control.
This culture is reinorced by top-leveltechnical, sales and logistics support toensure a total quality service to everycustomer.
4
API
Norsok M-710
Shell
Total
BS EN ISO 9001
BS EN 9100BAE Systems
Ministry of Defence
FDA
USP Class VI
...working to the
highest standards
and audited by
industrys most
exacting businesses
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Depth of experience
For further details, call your local contact shown on rear cover or email [email protected]
James Walker
products are found in
critical applications
at the forefront ofkey global industries
ensuring that
processes run safely
and smoothly, day
after day after day
Broad experience
James Walker is involved in designingsolutions and manuacturing products orvirtually every industrial sector.
Our products are ound wherever thereis a critical application, whether that ison the sea bed, at the very core o aprocess or ensuring saety under extremecircumstances.
Our applications and materialsengineering teams have developed in-depth knowledge o the industries weserve a knowledge that orms the basiso our engineered solutions and sets usapart rom the competition.
Our customers trust James Walkerproducts and solutions to keep theirbusiness working, their workorces saeand the environment protected.
In addition to third-party assessment orinternational quality standards, manyparts o our global operations are alsoregularly assessed and quality approvedby a wide range o industry bodies andindividual clients including multinationalcorporations, utilities and government
organisations.
Extreme environments
Our capabilities in high perormancematerials science are relied uponworldwide by customers who need topquality materials that are validated andproven to operate:
At extremes o pressure
In chemically aggressive and physicallyabrasive environments
Under rapid gas decompression (RGD)
conditions To the highest saety and perormance
speciications laid down by internationalindustry bodies
At extremes o temperature
Where ailure could have signiicanthealth & saety, environmental orinancial risk
In ood, pharmaceutical andbioprocessing applications wherecontamination prevention is critical
to the process
5
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Fugitive emissions
For further details, call your local contact shown on rear cover or email [email protected]
James Walker is an active member o
the European Sealing Association and
we have made a signiicant contribution
to the Associations Sealing
Technology Best Available Technique
(BAT) Guidance Notes.
This document, which is available asa ree download rom the ESA website,
gives the industry consensus guidance
on Best Available Techniques or
sealing; bolted lange connections,
rotodynamic equipment, reciprocating
shats and valves.
Saving energy & reducing costs
In helping to ensure eective and eicientemissions control, James Walker productscan also signiicantly reduce energyconsumption and costs.
We have the products, expertise andintegrated solutions to save you time andmoney when planning and implementingyour emission control plans.
James Walker products can cutequipment leaks dramatically and achieveeiciencies through reduced powerconsumption, better use o energy,improved water usage and better plantperormance.
In essence, the James Walker mission isto prevent pollution o the environmentthrough a range o products and servicesthat are environmentally riendly andwhich generate major beneits or yourbusiness.
Operators have to ensure that theirIPPC directive responsibilities are met,and substantial penalties apply ornon-compliance.
James Walkers experience andknowledge, allied to our range oleading edge products and services,makes us the ideal partner to helpyou comply with the IPPC and otherenvironmental directives.
Products & services
We have an extensive range o world-class products and services which meetor exceed the required internationalstandards in reducing volatile organiccompound (VOC) ugitive emissionsrom valves, pipelines, processing plantand pressure vessels. Many o theseproducts meet TA-Lut requirements anddemonstrate Best Available Technique(BAT) under the European Unions
Integrated Pollution Prevention andControl (IPPC) directive.
As a world leader in sealing and jointingtechnology, we have an in-depthunderstanding o the latest technologiesand products and can conirm whetherthe systems you have, or are planningto install, meet your emissionscontainment targets.
Reducing fugitive
emissions also
improves plant
performance and
reduces costs
Developing Best Available Technology
to protect your business and the environment
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Fugitive emissions
For further details, call your local contact shown on rear cover or email [email protected] 7
Equipment leaks rom valve glands
are considered to account or
approximately 50-60% o the ugitive
emissions on petrochemical sites.
Furthermore, the major proportion o
ugitive emissions comes rom only
a small raction o these sources.
For example, less than 5% o valves in
gas / vapour service can account or
more than 90% o the ugitive emissions
in a reinery.
Certiied products
A number o James Walker productshave been tested and certiied as meetingthe stringent TA-Lut requirements. TheGerman TA-Lut is a comprehensive airpollution control regulation that setsmaximum permissible limits or theemission o dust, vapours or gases whenprocessing, conveying or transerringdusty, liquid or gaseous materials, takinginto account the speciic risk potential.
Proven techniques
Even using the best certiied productsdoesnt guarantee the reduction orelimination o hazardous ugitiveemissions. To be successul in this taskrequires the correct procedures, ittingand maintenance techniques.
Product speciication
Regular monitoring and inspection
TA-Lut certiied products include:
Supagra Premier and SupagraControl compression packings
Metalex spiral wound gaskets
Metakamm Kammproile gaskets
Bolting regimes
Joint / lange protection
These are just a ew o the key areas inwhich James Walker can provide provenexpertise and valuable advice whenyou are seeking to comply with ugitiveemissions regulations.
James Walker is deeply committedto environmental excellence. Many othe products and services we supplyworldwide are expressly developed tohelp industry meet ever more stringent
environmental targets by:
Reducing ugitive emissions
Helping companies meet the EuropeanUnion IPPC and other internationalemissions directives
Improving the energy eiciency o plantand equipment
Attenuating noise and vibration
Class-leading solutions
Eliminating risk is all about using certified
product and proven techniques
Regular monitoring
and inspection
coupled with correct
seal specification is
the key to successful
fugitive emissions
control
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For further details, call your local contact shown on rear cover or email [email protected]
Elastomer products
Quality & traceability
Our Materials Technology Centre housesone o Europes most advanced acilitiesor elastomer batch production, materialsdevelopment and product testing.
We hold over 300 compound ormulaeproviding ull batch traceability,production lexibility and the highest levelso quality control.
Our products and materials areextensively in-house validated, and aretested, approved and speciied by endusers and equipment manuacturersaround the world.
Product availability
James Walker sealing products aresupplied in a variety o standard andspecialist grades o elastomer and othermaterials. I the products you want arenot available o-the-shel, we can design,manuacture and supply them creatingnew product moulds where necessary.
With our lexible production schedules, weare conident o meeting the most urgent
requests rom our customers anywherein the world. Our range o elastomericsealing products or valve applicationsincludes:
O rings
T seals
D seals
Dome seals
Diaphragms
In addition to our standard productconigurations, custom mouldings canbe designed and manuactured toindividual client speciications.
...over 300
compound formulae,
advanced in-house
batch production and
total traceability
Materials technology
We supply sealing products in a vastrange o general and high-speciicationgrades o elastomer including rangeso low-temperature and rapid gasdecompression (RGD) resistant materials.
Our comprehensive range o availablematerials includes:
Ethylene-propylene (EPM/EPDM)
Chloroprene / Neoprene (CR)
Nitrile (NBR)
Polyurethane (AU/EU)
Silicone (VMQ)
Fluoroelastomer (FKM)
Hydrogenated Nitrile (HNBR)
Perluoroelastomer (FFKM)
Within each material category wehave numerous dierent compoundseach specially ormulated or speciicapplications or operational conditionsincluding:
Extremes o pressure
Chemically aggressive environments
Extremes o temperature
Under rapid gas decompressionconditions
Abrasive environments
Case study
James Walker O rings in RGD(rapid gas decompression) resistantFR25/90 luoroelastomer arespeciied in valves or the underseapipeline that will eed SouthernEurope with Algerian natural gas.
The Medgaz projects 24-inchpipeline runs or 210km beneaththe Mediterranean in a maximumsea depth o 2160m, which meansthat RGD resistance is a primeconsideration or any seals inthe system.
Certiication o FR25/90 to Total GSVV 142 03/01 by French test houseCetim conirmed the materialssuitability.
Inflatable dome seals
Simple in design and low in maintenance, valves using adomed shut-o are used in a wide range o industries orcontrolling the low o bulk materials including abrasive,hazardous or toxic materials.
James Walker inlatable dome seals are available in abroad range o materials to suit every application andinclude silicone (VMQ), luorocarbon (FKM), nitrile (NBR),hydrogenated nitrile (HNBR), chloroprene (CR) andethylene-propylene-diene (EPDM).
Materials to FDA and other speciications are also available.
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For further details, call your local contact shown on rear cover or email [email protected] 9
Elastomer products
A range o industryapproved products
Aflas FEPM
AF69/90: compounded or rapid gasdecompression (RGD) resistance.
Elast-O-Lion HNBR
Elast-O-Lion101: Norsok M-710 or RGDresistance and sour gas (H
2
S) ageing.Total spec: GS PVV 142Shell spec: DODEP 02.01 B 03.02
Elast-O-Lion 985: compounded or RGDresistance and extreme low temperatureduties, down to -55C.
Fluoroelastomers FPM/FKM
FR58/90: Norsok M-710 or RGDresistance and sour gas (H
2S) ageing.
Total spec: GS PVV 142Shell spec: DODEP 02.01 B 03.02
FR25/90: Norsok M-710 or RGDresistance and sour gas (H
2S) ageing.
Total spec: GS PVV 142Shell spec: DODEP 02.01 B 03.02Cold temperature compatible.
Kalrez FFKM
The ultimate perormance material whenconsidering heat and chemical resistance.
Elast-O-Pure (EPDM)
Developed to USP Class VI or the
pharmaceutical and bioprocessingsectors.
FR68/90
This luorocarbon-based material isthe irst in our New Generation o oiland gas elastomers. With new polymerarchitecture, it oers best in classresistance to sour gas, amines andsteam or an FKM elastomer with thisoutstanding level o RGD resistance.It has a perect 0000 Norsok RGD rating
up to at least 10.0mm cross section at100C and also at 5.33mm section at anelevated temperature o 150C.
Norsok M-710 qualiication
Problems with RGD are most commonlyexperienced in the oil and gas industrybut can occur in any application wherethere is a rapid drop in gas pressure.
Rapid Gas Decompression (RGD) candestroy standard elastomeric seals in oiland gas applications downhole, at thewellhead and upstream.
Global operators and equipmentmanuacturers in the oil and gassector thereore rely on the enhancedcapabilities o James Walkers RGDresistant materials or extremeoperating conditions.
Operators such as Shell and Totalhave validated James Walker materialsagainst their own speciication inaddition to globally recognised industryapprovals. Norsok M-710 is one o
the toughest RGD testing regimes. Itcombines rapid gas decompressiontests and an evaluation o sour gas (H
2S)
ageing, enabling lie predictionsto be made or application conditions.
This is o immense value to operatorsin the North Sea, Caspian Sea,Middle East, and many sour ieldsacross the world.
Under Norsok test conditions atheoretical service lie o 817 years at80C has been predicted or JamesWalkers FR58/90 in sour gas service,beore its tensile strength is halved.
We are able to oer a range oproducts in both hydrogenated nitrile(HNBR) and luoropolymer (FKM)materials qualiied to Norsok M-710 orexceptional sealing perormance underarduous conditions.
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For further details, call your local contact shown on rear cover or email [email protected]
Expertise & experience
Industries across the world rely onour packings to help keep their valvesoperating eiciently day-in and day-out with energy saving beneits and theminimum o ugitive emissions.
James Walkers constant advances inmaterials and lubricants, product designand manuacturing techniques, bring youcompression packings to match both your
modern luid handling systems and yourolder plant.
Whatever your requirement our expertiseand over 125 years o experience incompression packing materials canbe brought to bear on providing acustomised solution.
Packed glands
The packed gland stands the test otime as:
An exceptionally reliable luidsealing device
Simple to install and maintain
Highly versatile
Remarkably cost eective in bothdowntime and materials especially
when compared to complex alternatives
Leading solutions
James Walker manuactures manydierent grades o compression packingor valve stem duties providing a broadrange o operational beneits:
World-beating ugitive emissioncontrol oten to below 50ppm
Best value luid sealing or your speciicplant duties
State-o-the-art materials to traditionalnatural yarns
Work in the most abrasive andchemically aggressive environments
Tolerate poor mechanical conditions
Meet requirements or potable water,ood, pharmaceutical or liquid/gaseousoxygen duties
Reduce your stockholding levels, asone packing can oten can be used or
many dierent valves and other luidhandling plant at a site
Supagra Premier A world-leading historyo success in beating ugitive emission control
speciications.Emission levels < 500ppm when subjected to over 12,000 valveoperating cycles with methane at 4MPa / 40bar.
Top o its class in comparative tests run by the Materials TechnologyCentre o Akzo Nobel. Leakage rates between six and 100 times lessthan competitors brands lasted 12 times longer than the nextbest valve packing.
Twice certiied to TA-Lut requirements in independent tests:
< 10-4 mbar.l/(s.m) at system temperatures below 250C
< 10-2 mbar.l/(s.m) above 250C
Third-party veriied or emission control by CETIM to ShellSPE 77-312 Class A speciication.
James Walker compression
packings can be supplied in length
orm or as pre-ormed split and
endless rings. Combination and
live-loaded ring sets are available in
a number o materials to suit speciic
applications.
Compression packings
World-leading
fugitive emission
control products
with proven
performance
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Supagra RibbonPak M tested to30MPa or use in super criticalpower stations.
Latest tests rate Supagra RibbonPak Mor use to 650C or 30MPa/300bar with noimpairment to valve stem movement. We alsohave independent proo rom Australian powerstations o successul operation at 540C with
simultaneous 23MPa/230bar pressure. Underthese conditions the product still oeredlong-term eiciency to match the steam valveconditions.
A range o industryapproved products
Supagraf Control
TA Lut / VDI 2440ISO 15848-1IPPC Best Available Technique (BAT)
Supagraf Moulded Rings
WRAS approved or hot and cold
potable water
Supagraf Premipak
Conorms to Shell MESC SPE 85/203 and85/204 material speciications
Fluolion Filament D
Meets FDA requirements, and is approvedby BAM and WRAS
Supagraf Premier
TA Lut / VDI 2440
API 622
Shell SPE 77-312 Rev 06.2007Class B rating
Shell SPE 77-312 Rev 06.10.2002Class A rating
API 607 Fire Saety to extendedspeciication
IPPC Best Available Technique (BAT)
Product name FoodMarine
servicesMetallurgical Petroleum
Pulp &paper
Powergeneration
Water &sewage
Arasele 7 3 3 3 3 3 3
Duramid 3 3 3 3 3 3 3
Fluogra 3 3 3 3 3 3 3
Fluolion Emulsion XA-P 7 3 3 3 3 3 3
Fluolion Filament L 3 3 7 3 3 3 3
Hornet 3 3 3 3 3 3 3
Liongra 3 3 3 3 3 3 3
Ramiex 7 3 3 3 3 3 3
Supagra Moulded Rings (steam) 3 7 3 3 3 3 3
Fluolion Filament D 3 3 7 3 3 3 3
Grapak 7 3 3 3 3 3 7
Supagra Control 7 3 3 3 7 3 7
Supagra LF Rings 7 3 3 3 3 3 7
Supagra Premier 7 3 3 3 7 3 7
Supagra PremiPak 7 3 3 3 7 3 7
Supagra RibbonPak M (steam) 7 3 3 3 3 3 7
Supagra Tape 3 3 3 3 3 3 3
Compression packings
Applications
More than 125 years of experience
in the manufacture and application
of compression packings
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For further details, call your local contact shown on rear cover or email [email protected]
Gaskets
Kammprofile
The James Walker Metakamm gaskettype is generally a solid metal ring havinga serrated tooth orm proile on each side.
A covering layer o graphite or PTFE isapplied, which becomes compressed intothe serrated surace when the gasket isloaded.
Saer and easier to handle than spiral-wound
Operate at up to 1000C or25MPa/250bar
Non-metallic cut gaskets
Compressed fibre
Most luid media rom ASME Class 150 toClass 600 ratings.
Chietain carbon ibre / NBR
Centurion glass / aramid / NBR
Sentinel aramid / NBR
Inca glass / aramid / NBR
Expanded graphite
James Walker Supagra combinesexcellent chemical resistance with anexceptionally wide temperature range orsealing integrity over extended periods.Supagra grades include:
Standard 98% pure
Ultra-pure / nuclear grade
Tanged
Laminated
PTFE
Outstanding chemical resistanceor duties where hygiene and non-contamination are essential.
Fluolion
GORE
Teadit
Gylon
Elastomer
James Walker oers a broad range ocommercial and speciication gradeelastomer jointing materials including:
Natural rubber (NR)
Nitrile rubber (NBR)
Ethylenepropylenediene (EPDM)
Silicone (VMQ)
Fluoroelastomer (FKM)
Perluoroelastomer (FFKM)
Semi-metallic
Spiral-wound
The Metalex range o spiral-woundgaskets is widely used on high pressure
joints including Metalex type C and C/IR invalve bonnet and steam trap applications.
These are generally used or highertemperatures and pressures. A variety ometals are available or the winding stripas well as or the support rings.
System pressures: high vacuum to over35MPa/350bar
Temperatures: cryogenic to 1000C
Material combinations or all operatingconditions
James Walker oers two semi-metallicmulti-purpose gaskets certiied as FireSae to ANSI/API Standard 607 andISO 10497-5:2004, or critical CPI / HPIapplications.
CorruSafe FS
Stainless steel corrugated ring
PTFE inner envelope
Graphite outer seal
Maximum pressure 5MPa/50bar
Metaflex SG/IR Fire Safe
Spiral-wound construction
Stainless steel inner support ring
PTFE inner seal and winding strip
Graphite outer seal
Carbon steel outer ring
Maximum pressure 35MPa/350bar
Sizes rom to 48 to all relevant gasketstandards and lange designations.
Continuous operating temperatures o upto 260C.
Fire Test certiication to API 607 ISO 10497
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For further details, call your local contact shown on rear cover or email [email protected] 13
Gaskets
Metallic ring joints
Manuactured to the highest standardsincluding API 6A, Moorside ring typemetallic gaskets are used or hightemperature or pressure applications inthe oil, gas and process industries.
Only the best orged metals are usedin manuacturing Moorside ring jointgaskets no welded rings. All ringsundergo a stringent machining process to
ensure that close tolerances and smoothcontact suraces are rigidly maintained.
Standard materials
Sot iron
Low carbon steel
Alloy steels
Stainless steels
Specialist materials
High nickel alloys (eg, Incoloy)
Super alloy steels (eg, Inconel)
Quality is guaranteed by a strict series otests and process quality control plus ainal inspection to assure total compliancewith customer speciications.
Traceability o material and constantmonitoring o manuacture are essentialor eective quality control. All Moorsidering joint gaskets carry a MaterialReference Number, which directly relatesto the batch o material rom which it was
manuactured.
API 6A, ASME B16.20, and customring joints
Manuacture in the UK by API licensee
R type (oval and octagonal)solid sections
RX and BX or pressures over70MPa/700bar
Wide ranges o materials
R type oval joint with elastomer coating.
The lips o the elastomer seal on the BX ring joint arepressure energised (the ring is made taller than standard
to give a stand-o) and thus a lower bolt load than normalcan be used to achieve a seal or a hydro-test.
Elastomer coated ring joints or pressuretesting operations
Elastomer coated ring joints areused or pressure testing purposes,minimising the risk o damaging the
sealing aces. Once the testis completed a metal ringjoint, available in R (ovaland octagonal), RXand BX conigurationsdependant uponapplication, can then beitted or inal service.
Metalex spiralwound or Metakammkammproile gaskets can
also be used or pressuretesting; located betweenthe lange aces inboard othe ring joint groove. Again,this coniguration minimises the risk ogroove damage during pressure testingahead o inal assembly.
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Valve seating
For further details, call your local contact shown on rear cover or email [email protected]
Thermoplastic seats
Increasingly stringent restrictions on valveoperating conditions over the years havemeant the use o several thermoplasticmaterials to cover the required operatingrange or valve seat inserts.
However thermoplastic materialscan cover such a broad range ospeciications that there is oten a certainamount o conusion and ambiguity as to
the exact material used and its associatedcapabilities.
Working closely with a major valvemanuacturer, James Walker Devoldeveloped and introduced Devlon V-APIgrade as a superior valve seat material,which is now widely speciied by valvemanuacturers and also approved or useby major oil and gas producers such asShell and BP.
Devlon V-API
DevlonV-API is part o the polyamideamily but incorporates additives whichallow it to perorm at higher pressures andtemperatures than other grades o Nylon.
Devlon V-API beneits
Devlon V-API can be speciied as adirect replacement or Nylon as a valveseat material in the knowledge that itexceeds all temperature and pressurelimitations o Nylon 6, Nylon 6/6,Nylon 6/12 and Nylon 12.
Devlon V-API oers a range ooperational beneits:
Approval to Total GS EP PVV 142 rev4
Proven in operation over a temperaturerange rom -196C to +200C (-315F to+392F), and at a pressure o 414bar(6000psi) at +176C (350F), subject tovalve and seat design.
Available in dimensions o 1 (25.4mm)to 77 (1955.8mm)
OEM speciied
Cost eective
Available in semi/inished machined andbillet ormats
Material choice
Elastomers
Wide range o elastomer compoundsavailable to match speciic applicationcriteria.
Devlon V-API
Robust alternative to PTFE and Nylongrades suitable or use at higherpressures.
NylonFull range o Nylon grades available orstandard valve applications.
PTFE
Chemically compatible with the majorityo media.Glass reinforced PTFE
Oers good chemical resistance o virginPTFE with extended lie.
UHMW polyethylene
Ultra-high molecular weight polyethylene,ideal or use in low-level radiationapplications, also oers excellentresistance to abrasive media.
PCTFE
For extreme low temperature applications.
PEEKTM
For high temperature and pressureservice, suitable or nuclear applications.
Metals
Machined or spun metal seat inserts are
ideal or applications involving hydraulicshock, high temperature or abrasivemedia. Vast range o specialised metalsand coatings available to suit individualapplications.
A Devlon V-API valve seat andhigh perormance elastomer
O ring sealing arrangement.
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Valve seating
For further details, call your local contact shown on rear cover or email [email protected] 15
DifferentialPressur
e
PSI/(Bar)
TemperatureF /(C)
Nylon
6
PEEK
PTFE
6500(448)
6000(414)
5000(345)
4000(276)
3000(207)
2000(138)
1000(69)
0
0(-18)
100(38)
200(93)
300(149)
400(205)
500(260)
600(316)
DevlonV-A
PI
Pressure / temperature perormance comparison
Devlon V-API offers
better performance than
Nylon or PTFE and is
significantly more
cost-effective than PEEK
Metallic seats
When leak-tight perormance is required under severe service conditions such as high temperature or pressure or with corrosive or
abrasive media, then metallic seats can be precision machined to customer speciication rom a wide range o specialist metals to suitthe individual application.
James Walker is highly experienced in the precision machining o diicult-to-work exotic alloys, as well as all standard grade materials.Materials machined regularly and usually held in stock include;
Stainless steel
Duplex
Super duplex
Hastelloy
Inconel
Monel
Titanium
Bronze
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PTFE Chevron & KVSP
For further details, call your local contact shown on rear cover or email [email protected]
PTFE Chevron Packing Sets
Chevron (known as Shallex in someregions) is our universal multi-lip packingthat is highly regarded or its long workinglie and ability to operate under adverseconditions. When used in split orm it canprovide major downtime savings.
PTFE is the standard material used inautomatic control valves because o itsbroad chemical compatibility, excellent
thermal stability and reduced torquerequirements on valve activation.
PTFE Chevrons orm a multi-part packingset commonly made up o a centre sealingring with top and bottom (male and emale)adapters.
Service capabilities
Max operating temperature: +260C
Min operating temperature: 0C
Max system pressure: 42MPa/420bar
Chemically inert and suitable or mostmedia in the pH 0-14 range
Chevron sets can be supplied as live-loaded kits. The spring loading helps;
Improve perormance
Compensate or stem wear, pressure andtemperature changes
Kalrez Valve Stem Packing(KVSP)
KVSP is the Kalrez Valve Stem Packingsystem rom DuPont PerormanceElastomers.
It comprises alternate V-rings o Kalrezperluoroelastomer (FFKM), and rings oDuPont Telon or DuPont Vespel to orma three or ive-part packing set.
The KVSP system is widely used tominimise ugitive emissions, particularly incontrol valves. A ive-part set can typicallyreduce valve stem leakage to less than10ppm at oil, gas, petrochemical andchemical processing plants.
Standalone packing sets and calibrated
live-loaded kits, together with full
technical support, are supplied by
James Walker as an Authorised
Distributor of Kalrez parts in the UK.
16
Case Study
Application1 level-control valve itted on areactor vessel operating at 30Cand 4.5MPa/45bar with a mixtureo pentane and butane plus trace
solvents, water and acid.
ProblemTen years o continual problems withvalve stem sealing. Graphite-basedstem packing oered little success,ailing soon ater installation. Ceramic-coated stems were eventually itteddue to stem damage. On averagethe valve caused a reactor shut-downat least once a year at a cost o over60,000 a time.
Requirement
Packing system oering eectivelong-term luid sealing and accuracyo control or the valve.
SolutionJames Walker reurbished the valve,itting KVSP seals lubricated withDuPont Krytox, reinstalled andmonitored the unit. Ater two and a halyears continuous service the KVSPset is still operating perectly.
BeneitsImmediate operational saving in
excess o 60,000 per year plusimproved productivity and saety.
KVSP capabilities
Chemical properties
All KVSP components display outstandingchemical resistance being inert to media inthe range pH 0-14.
Service capabilities
KVSP systems are rated or actualcontinuous temperature service rom-40 to +288C. Live loading is necessary
to seal to -40C
Max system pressure: 17MPa/170bar
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Spring energised PTFE lip seals
For further details, call your local contact shown on rear cover or email [email protected] 17
Spring action
On installation the spring element isunder compression and orces the sealinglip against the counterace to create aleak-ree seal. Any set or wear in the sealmaterial, or eccentricity in the suraceagainst which the seal is made,is compensated or by the springenergising action.
The spring elements o these seals are
available in a variety o materials toprovide the required perormance andchemical resistance to suit dieringapplications and environments.
Materials available include:
Stainless steel
Hasteloy
Inconel
Critical applications
Due to its unique properties the springenergised PTFE lip seal is the idealsolution or a great variety o applications:
Extreme temperatures
Aggressive environments
Food and pharmaceutical
Oshore
Chemical processing
Rerigeration
Energy
Aviation
Deence
High perormance
High-perormance spring energised
PTFE lip seals rom James Walker have
been developed to meet the demands o
extreme applications, which are beyond
the limits o elastomers and packings.
Capable o handling adverse service
conditions these seals are used where
chemical compatibility, extremes o
pressure and temperature, and ultra lowriction are required.
Material properties
The molecular structure o PTFE provides
a seal material that is not only chemically
resistant but that is almost totally resistant
to the eects o rapid gas decompression
(RGD).
In addition, the almost identical static
and dynamic riction coeicient o
PTFE means that the stick-slip eect is
eliminated, even at low temperatures,
which is ideal or smooth valve operation.
Product benefits
Virtually universal compatibility with all
luids and gases
Suitable or operational temperatures
rom -250 C to +250 C
Does not absorb water
Unlimited weather resistance
Doesnt age in atmosphere or light
Excellent low-stick properties
Long service lie
RGD resistant
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Comlex metallic bellows
A metallic bellows seal is usuallyused in place o conventional packingwhere conditions are too harsh orother alternatives or the elimination oleakage is critical; or example, in nuclearapplications.
This sealing option eliminates ugitiveemissions o toxic, lethal, or regulatedluids/gases, minimises maintenance,
reduces lie cycle costs, and optimisesproductivity in process plants includingsteam, cryogenic, and vacuum systems.
With this sealing option there are nosliding or rotating seals through whichprocess luid can pass. The bellowssimply expand or compress with thestroke movement o the valve, anyrequired movement is taken up by theconvolutions in the bellows.
Metallic bellows
For further details, call your local contact shown on rear cover or email [email protected]
Total Cost o Ownership
Designed to last many thousands ocycles, Comlex bellows oer a long-term sealing alternative with none othe continual maintenance demandsassociated with other methods o valvestem sealing.
Although requiring a higher initial outlaycompared with alternative stem sealingproducts, Comlex metallic bellows
can provide the lowest Total Cost oOwnership (TCO) o any sealing system.
18
The Comlex metallic bellows, shown
here in a globe valve application,
eliminates loss or contamination o
the process media.
Best Available Techniques
Metallic bellows can be used with virtuallyany media, guarantee zero media loss andhave a long lie expectancy.
Bellows seals are considered a BestAvailable Technique (BAT) or the controlo ugitive emissions and also prevent theprocess media rom contamination byharmul or corrosive external conditions.
Typical life expectancy:
Gate valve bellows 3,000 cycles
Globe valve bellows 10,000 cycles
Comlex metallic bellows rom JamesWalker are high speciication products,ormed rom assured quality tube andavailable in a variety o materials including:
Stainless steel
Inconel
Hastelloy
Monel
...provides the lowest cost of ownership
for valve stem sealing
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Specialised metal components
For further details, call your local contact shown on rear cover or email [email protected]
Precision machining
James Walker supplies proprietarycomponents and standard items toexacting speciications on a global basis,including:
Valve bonnets
Valve seats
Valve seat carriers
Valve balls
Metal to metal seals
Major operators and OEMs in the oil andgas sector have relied on our renownedengineering expertise and skilledworkmanship or over 40 years in theproduction o API metal ring joint gaskets.
Established market leader in themanuacture o ring joints, metal sealsand bespoke metal components orOEM and end-user clients
Providing services on a 24/7 basis, 365days a year, to meet customers mosturgent demands worldwide
Quality Assured API spec 6A PSL4 licence No. 6A-0038
API spec Q1
API accreditation in accordance withStandard 17D
Full materials traceability
Materials sourced rom trusted supplychain, ully certiied with permanentrecords held
All machining undertaken is ullycontrolled in-house
NDT, coatings and heat treatmentconducted by approved and certiiedsubcontractors
Materials
We are highly experienced at themachining o diicult-to-work exotic alloys,as well as all standard grade materials.The ollowing is an inventory o metals that
we machine regularly many o these wehold in stock.
Stainless A182 F316
Duplex A182 F51
Super duplex A182 F53
Super duplex A182 F55
Stainless Nitronic 50 XM19
Inconel 825
Inconel
625
Hastelloy C 276
Monel K 500
Titanium
Coatings & treatments
Where required or reasons such aswear resistance, chemically or physicallyaggressive media or riction reduction,components can be inished with a wide
range o coatings and surace treatments,including:
Xylan luoropolymer
Zinc phosphate
Molybdenum disulphide
Silver
Gold
Zinc
Nitriding
Vacuum annealing
Stress relieving
19
...expertise in
thinwall machining
and exotic alloys
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Tension control bolting
For further details, call your local contact shown on rear cover or email [email protected]
Leading technology
Tension control is essential in achieving100% reliability. Our unique RotaBoltasteners not only achieve the correcttension at installation, they maintain thisthroughout the lie o the bolted joint.
RotaBolt tension control asteners areindividually 100% load test calibrated andevery bolts extension measurement isindividually certiied.
Joint integrity
A broad range o beneits can be derivedrom maintaining reliable bolted jointintegrity.
Reduced maintenance costs
Better design eiciencies
Reduced installation costs
Improved saety
Reduced build costs
Enhanced design perormance
Lowest cost o ownership
Greener environmental regimes
Extended equipment lie
Leak ree environments
RotaBolt tension control asteners assurejoint integrity wherever bolted joints aresubject to pressure containment, vibrationloosening, atigue and structural slippage.
Pressure containment
RotaBolts are providing joint integrityon pressure vessels, reactors, heatexchangers and high integrity pipelinelanges. Our technology is helping to
make leak-ree environments a reality.
Fatigue
Bolted joints that are subject to cyclicalloading are vulnerable to atigue ailure.Failure occurs when bolts are tightenedwith insuicient bolt tension the cyclicload exceeds the atigue strength o thebolt, resulting in a atigue crack.
In process engineering and powergeneration RotaBolt asteners are leadingthe way in regimes that are it and orget.
Case Study
ApplicationNon-return valve carrying steam at 300oC in a nuclear power plant. The valveis pressurised during start-up o the plant to 16MPa/160bar but ater threedays the pressure reduces to a continuous 6.4MPa/64bar.
ProblemThe valve suered rom heavy lange rotation due to pressure on start-upand had been leaking or a period o seven years.
SolutionRotaBolt tension control asteners were installed to ensure correct jointtension and optimum seating and loading o the gaskets. As a result o thissolution the valve was completely leak ree on start-up and it has remainedleak ree ever since (more than three years and counting).
The rotating cap o the RotaBolt
provides a simple, oolproo check
o correct bolt tension.
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RotaBolt Vision
The worlds irst saety bolt to give a clear,visual indication o loss o tension acrossthe bolted joint.
The Vision operates on the same internalair gap technology as the original RotaBolt
but has a specially developed, visualindicator which appears as an unbrokenyellow line across the head o the bolt.
As soon as any tension is lost across thebolt, the indicator instantly rotates by90 degrees to show a distinct right anglebreak in the yellow line.
This is clearly visible up to 25 metres awayand is ideally suited or bolted joints inlocations such as sea-bed valves whereremote inspection by camera can be used.
Tension control bolting
For further details, call your local contact shown on rear cover or email [email protected] 21
Original RotaBolt
Standard bolts rom M12 to M135 canbe converted to incorporate the uniqueRotaBolt indicator eaturing air gaptechnology.
Increased tension accuracy means thatbolt quantity, diameter or strength gradecan be reduced.
There is less machining, ewer holes
drilled and ewer bolts to be tightened.
In on-site installations it is the quickestsystem to achieve assured designtension, reducing installation times by aactor o six.
It reduces all aspects o bolted jointmaintenance, delivering quick and easyin-service monitoring and eliminatingoperational irst aid.
No operator skill is required.
It empowers you to set bolt load andguarantee bolt tension throughout all yourplant and machinery.
RotaBolt 2
RotaBolt 2 provides an even greaterrange o tension control on installationtightening and in-service checking byoering two tension settings in a singlesensor.
It eatures a dual load indicator cap theouter cap or high tension setting and
the inner cap or low tension. This givesyou the choice o an operational tensionrange, either or overload or maintenancecontrol.
RotaBolt 2 has proven perormance inoshore, petrochemical and nuclearapplications.
Critical Factors
Bolted joint integrity relies on threecritical actors:
Joint design
Bolt quality
Tension control
The irst two o these actors arecontrolled and measured.
The majority o bolted joints howeverare tightened in an uncontrolledmanner and the bolt tension achievedat the end o the tightening cycle isunknown.
Traditional tightening methods, suchas torque and hydraulic tensioning,measure the eort applied and notthe tension achieved across the
bolted joint.
The operator may well be highlytrained and the installationprocedures ollowed to the letter,but ailure can still occur i all threereliability actors are not properlymeasured.
90 95% o all bolted joint ailures areattributed to insuicient bolt tensionon installation.
It is tension control that is critical to
the reliability and saety o boltedjoints.
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Services
For further details, call your local contact shown on rear cover or email [email protected]
Evaluation
Historic data collection
Pressure/temp media data
Flange, bolt & gasket details
Bolted joint evaluation
Design
Product combination & selection
Determination o optimal sealingparameters
Recommendations i housing /
metalwork modiications needed
Accurately establish required seatingloads
Beneits
Reduced downtime
Assured reliability Reduction o lost product
Leak & emission containment
Elimination o repetitivemaintenance costs
International contracts
Major players in a broad range oindustries including the metallurgical,power generation, chemical andpetrochemical processing sectors, relyon product supply and technical supportprovided by James Walker.
The long-term contracts we orge withthese multinational corporations coverthe requirements o their plants across
many continents; our IT systems andlogistics operations providing the secure,integrated supply chain required by suchorganisations.
The aim o a service contract is to helpyou keep your plants running saely andeiciently, and to oer you signiicant costsavings based on:
Sealing products and associatedcomponents supplied at highlycompetitive market prices
Value added services includingtechnical advice, problem solving,Total Cost o Ownership (TCO)programme
Stock standardisation andrationalisation especially where yourplants use many dierent products oridentical duties
Eicient order processing, logistics,stockholding and IT support ore-supply to help you meet JITrequirements and reduce plant
downtime
Valve & Flange Management
The Valve & Flange Management Programme approach Evaluate, Design andApply is aimed at delivering long-term solutions where the cost beneits speak orthemselves, as opposed to short-term ixes that need to be applied again and again,at considerable cost.
Improving safety
and productivity
whilst reducing
Total Cost
of Ownership
Delivering
long-term solutions
with significant
cost benefits
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Technical guides & data sheets
For further details, call your local contact shown on rear cover or email [email protected] 23
These guides give detailed technical inormation on the products and services supplied by James Walker or valve applicationsacross a broad range o industries. Please ask or your copies, or visit our website www.jameswalker.biz where many o them can bedownloaded in pd orm.
Trademark acknowledgements
James Walker acknowledges the ollowing trademarks as mentioned in this publication. All other names bearing the symbol aretrademarks o James Walker.
Alas Asahi Glass
Gylon Garlock Sealing Technologies
GORE WL Gore & Associates
Hastelloy Haynes International
Incoloy Special Metals Corporation
Inconel Special Metals Corporation
Kalrez DuPont Perormance Elastomers
KVSP DuPont Perormance Elastomers
Monel Haynes International
Nitronic Armco Inc
PEEKTM Victrex plc.
Stellite Deloro Stellite Inc
Teadit Teadit International
Telon DuPont Perormance Elastomers
Vespel DuPont Perormance Elastomers
Viton DuPont Perormance Elastomers
Xylan Whitord Corp
O Ring Guide
High Performance Sealing Technology
The comprehensive guide to O ringsealing systems including
O ring selection
General & high performance materials
Housing design & tolerances
Cords, kits & lubricants
Issue 6
Elastomeric seals & components forthe Oil & Gas industry
High Performance Sealing Technology
World-leadingsealingtechnology
Highintegrityproductsforsafety,environmental&revenueprotection
RGD-resistantelastomersqualifiedtoNorsok M-710
Globalstockholding&support
Proventrackrecord
Issue 8
Compression Packings Guide
High Performance Sealing Technology
The comprehensive guide to compression packings for
Pumps Valves Hatch lids Crucible lids Furnace doors
Gland sealing duties
Hydraulic Sealing Guide
High Performance Sealing Technology
Rod/glandseals
Pistonseals
Wipers&scrapers
Bearing strips
Orings
Issue 28.1
James Walkers comprehensive
guide to quality gasket products
for industry worldwide
Gaskets & Jointings Guide
High Performance Sealing Technology
Issue 5.1
O Rings
Gaskets & Jointings
Devlon V-API
Elastomeric Seals
Gasket Technology
RotaBolt
Dome Seals
Gasket Guide
IPPC
Compression Packing
Specialised Metals
Global Contracts
Hydraulic Seals
Metallic Bellows
Flange Management
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James Walker AustraliaTel: +61 (0)2 9721 9500Fax: +61 (0)2 9721 9580
Email: [email protected]
James Walker Benelux
(Belgium)Tel: +32 3 820 7900Fax: +32 3 828 5484
Email: [email protected](Netherlands)Tel: +31 (0)186 633111Fax: +31 (0)186 633110
Email: [email protected]
James Walker BrasilTel: +55 21 2220 2152Fax: +55 21 253 11704
Email: [email protected]
James Walker China
Tel: +86 21 6876 9351Fax: +86 21 6876 9352
Email: [email protected]
James Walker Deutschland
Tel: +49 (0)40 386 0810Fax: +49 (0)40 389 3230
Email: [email protected]
James Walker FranceTel: +33 (0)437 497 480Fax: +33 (0)437 497 483
Email: [email protected]
James Walker Iberica
Tel: +34 94 447 0099Fax: +34 94 447 1077
Email: [email protected]
James Walker Ireland
Tel: +353 (0)21 432 3626Fax: +353 (0)21 432 3623
Email: [email protected]
James Walker ItalianaTel: +39 02 257 8308Fax: +39 02 263 00487
Email: [email protected]
James Walker Mfg Co. (USA)
Tel: +1 708 754 4020Fax: +1 708 754 4058
Email: [email protected]
James Walker New ZealandTel: +64 (0)9 272 1599Fax: +64 (0)9 272 3061
Email: [email protected]
James Walker Norge
Tel: +47 22 706 800Fax: +47 22 706 801
Email: [email protected]
James Walker Oil & Gas (USA)
Tel: +1 281 875 0002Fax: +1 281 875 0188
Email: [email protected]
James Walker SingaporeTel: +65 6777 9896Fax: +65 6777 6102
Email: [email protected]
James Walker South Africa
Tel: +27 (0)31 304 0770Fax: +27 (0)31 304 0791
Email: [email protected]
James Walker worldwide support and distribution
General inormation
Health warning: I PTFE or uoroelastomer (eg, FKM, FFKM, FEPM) products are heated toelevated temperatures, umes will be produced which may give unpleasant eects, i inhaled.Whilst some umes are emitted below 250C rom uoroelastomers or below 300C rom PTFE,the eect at these temperatures is negligible. Care should be taken to avoid contaminatingtobacco with particles o PTFE or uoroelastomer, or with PTFE dispersion, which may remainon hands or clothing. Material Saety Data Sheets (MSDS) are available on request.
Inormation in this publication and otherwise supplied to users is based on our generalexperience and is given in good aith, but because o actors which are outside our knowledgeand control and aect the use o products, no warranty is given or is to be implied with respectto such inormation. Unless governed by type approval or contract, specifcations are subject
to change without notice. Statements o operating limits quoted in this publication are not anindication that these values can be applied simultaneously.
To ensure you are working with the very latest product specifcations, please consult therelevant section o the James Walker website: www.jameswalker.biz.
James WalkerCustomer Support Centre1 Millennium Gate, Westmere DriveCrewe, CW1 6AY, UKTel: +44 (0) 1270 536 000Fax: +44 (0) 1270 536 100
Email: [email protected]