LESSON

7
LECTURE
VALVE MAINTENANCE AND VALVE
PACKING
SUB-OBJECTIVE
At the end of this esson! the t"#inee $i %e #%e to de&onst"#te #n
'nde"st#ndin( of V#)e M#inten#n*e #nd V#)e P#*+in(,
-,. VALVE DISASSEMBL/
-,. PREPARATION 0OR DISASSEMBL/
After checking that the valve is isolated and tagged out, the first step in
disassembly is a thorough cleaning of the outside of the valve. This
cleaning task is important; it minimizes the amount of foreign matter that
gets into the valve and piping system.
Later, before reassembly all foreign matter will have to be removed from the
inside of the valve. It is much easier to remove dirt from the outside of the
valve now than to clean it from the inside before reassembly.
leaning methods vary with the valve and operating conditions. !ire
brushing is usually sufficient, but it may be necessary to wipe away any
loose material with a clean rag. In some cases, the outside of the valve
may have to be washed. The most important areas to clean are the flange
mating surfaces and the area around the gland follower.
In this section, the valve to be disassembled is a regular globe valve, which
is common to industrial plant use. "ig. #$% illustrates the parts of the globe
valve to be described during disassembly.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' % /AL/'- A). /AL/' &AI)T')A)'
0i(, 7--, Go%e V#)e,
-,1 REMOVAL
The first step is to loosen the put on the handwheel 2"ig. #$34. Then the gland
nuts 2"ig. #$54. *n both sides and the bonnet nuts 2"ig. #$34 are loosened. It
is easier to loosen these nuts now than when the bonnet is separated from the
valve body. )e6t, the gland nuts are unscrewed and removed to relieve
pressure on the packing 2"ig. #$5. Then the bonnet nuts are taken off #$5.
This will allow for the removal of the handwheel and bonnet assembly.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 3
0i(, 7-1, Loosenin( the N'ts, 0i(, 7-2, Re&o)in( the N'ts
After the gasket is removed, the handwheel is rotated in the closed direction
as far as possible. )ow the nut and handwheel are taken off of the valve.
The valve stem is rotated until it is out of the bonnet. This can be done
manually or with the aid of a wrench. If a wrench is used, care must be taken
not to damage the stem. A soft$faced wrench is good to use, or a piece of soft
material held between the wrench and the stem will protect the stem. The
stretch is applied between the disc and the back seat of the valve. Accidental
scratching of the stem with the wrench is not good, but it will not cause
leakage when the valve is reinstalled, since this part of the stem does not
come in contact with the packing.
(owever, if the wrench is applied above the back seat or on a threaded
portion of the stem, significant damage could result. A leak could develop or
the stem could become difficult to rotate, making the valve inoperable.
The packing gland will come off as the stem is rotated out of the bonnet.
!hen the stem is out, the packing can be removed. It is taken out with a
packing removal tool, or if the valve is small, the packing may easily come out
by turning the bonnet over and pushing it out of the stuffing bo6. "ig. #$7
illustrates the use of a packing removal tool.
0i(, 7-3, P#*+in( Re&o)#,
After the packing is removed, the bonnet and the stuffing bo6 can be cleaned
and inspected. The body and bonnet are checked for steam cuts and pits. If
any are found, they should be repaired through lapping if the damage is minor.
.eep cuts or pits may have to be machined on a lathe before lapping can be
done. The area to inspect for steam cuts and pits is shown in "ig. #$8.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' 5 /AL/'- A). /AL/' &AI)T')A)'
0i(, 7-4, Bonnet se#tin( #"e# ins5e*tion,
1,. LAPPING! SPOTTING-N! AND GRINDING-IN
The processes of lapping, spotting$in, and grinding$in are part of routine valve
maintenance. &ost minor cuts and pits can be removed through lapping and
grinding$in; the spotting$in test should always be performed to check the
mating of the valve seating area.
1,- LAPPING
To lap the seating surface of the bonnet, small amount of lapping compound is
first applied on the lapping block 2"ig. #$94. +sually, the process is begun with
a coarse grade of compound, changing gradually to a fine grade to achieve a
smooth, polished surface at the seating area.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 7
0i(, 7-6, A557in( L#55in( Co&5o'nd to Bo*+,
After applying compound to the lapping block, the bonnet is rotated in a figure$
eight motion, as illustrated in "ig. #$#, with care taken not to e6ert e6cessive
pressure on the bonnet. In lapping, the weight of the part usually provides
ade:uate pressure to smooth the surface. "re:uently, the bonnet seating
surface is checked by wiping the compound from it and inspecting it. The
process is repeated until the seating surface is smooth.
0i(, 7-7, L#55in( Motion,
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' 8 /AL/'- A). /AL/' &AI)T')A)'
"or e6ample, if too much metal is taken from the seating surface of the bonnet
or body of a valve, the gasket that fits between them will not be compressed
sufficiently. Leakage will result when the valve is put back into service.
.eep cuts or pits that cannot be removed by lapping may be filled in by
welding and then machined on a lathe. (owever, maintenance personnel
must usually decide if such action is worth the time that must be invested. In
some cases, it may be cheaper to replace the valve.
After refurbishing the seating surfaces of the bonnet and body, the valve disc
and seat are inspected for proper seating. *n inspection, if the disc and seat
are seating properly, there will be a clearly defined area to indicate this. If not,
it is :uite likely that the disc has not been seating properly, if at all, and that
the valve has been leaking.
1,1 SPOTTING-IN
A more accurate way to inspect the disc and seat for positive seating is
through the method of spotting$in.
&any discs rotate freely on the stem. This gives the disc a self$seating feature
and provides a good seal when the valve is closed. (owever, during spotting$
in, the disc must not be allowed to rotate. To prevent rotation, a piece of shim
stock can be used to hold the disc in place and prevent its movement. The
shim stock should be positioned between the stem and the disc. Another way
to prevent the disc from rotating is to take the disc out of the stem, put a piece
of shim stock between the disc and the bottom of the stem, and then
reassemble the disc.
To spot$in a valve seat, a thin coating of 0russian blue is applied evenly to the
surface of the disc. It is important to use a type of blueing that is non$drying.
;efore applying the blueing, the seat and disc must be cleaned. A light
grinding$in or lapping can be used to accomplish this cleaning.
1,2 GRINDING-IN
Imperfections to the disc or seat will re:uire that the part either be repaired or
replaced. -ome valves are e:uipped with replaceable parts. In this case, it
may be more economical to replace the disc and seat then to repair them.
(owever, if minor imperfections are found, it is best to make repairs. *ne
method for repairing minor damage to the seating area of a disc or seat is
called grinding$in.
1rinding$in is accomplished by applying a small amount of lapping compound
to the disc. The disc is placed on the seat and rotated back and fourth, using
a light downward pressure. The disc is moved forward one$:uarter turn
occasionally to ensure even grinding$in. This process is shown in "ig. #$<.
Lapping compound should be changed fre:uently, and finer grades should be
used as lapping progresses.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 9
0i(, 7-8, G"indin( in # Go%e V#)e Dis #nd Se#t,
A flat$surfaced disc, like the one on the gate valve illustrated in "ig. #$=, is
repaired in a different fashion. A lapping block can be used to remove minor
imperfections. Lapping compound is applied to the block, and the disc is then
placed on the block. The disc is rotated in a figure$eight motion, using the
same light downward pressure as before.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' # /AL/'- A). /AL/' &AI)T')A)'
0i(, 7-9, G#te V#)e Dis*,
The disc should be checked fre:uently during the grinding$in process. The
compound is removed, and then the disc is inspected. After the lapping
compound is wiped from the block and disc, the disc is rotated on the bare
metal block in a figure$eight as before. .ark areas on the surface indicate
areas where the disc is not seating properly. !hen lapping or grinding$in has
been completed, the seat and the disc should be spotted$in. Then the shim
stock 2if used4 should be removed from between the disc and the stem.
;riefly, then, the lapping and grinding$in processes are as follows> !hen the
original disc is rotated against the original valve seat, the process is called
grinding$in. !hen the disc is rotated against another surface, such as the
block, or a lapping tool is rotated against the disc, it is called lapping.
(owever, both processes use lapping compound to smooth out minor
imperfections to the seating surfaces.
The following important points should be kept in mind when lapping or
grinding in a valve>
a. )ever bear heavily on the lap or valve disc.
b. )ever bear sideways.
c. Always use clean lapping compound.
d. -pread the compound evenly and lightly.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' <
e. )ever lap or grind$in more than necessary.
f. ,otate to change the relationship of the disc or lap with the seat
fre:uently.
g. Always grind$in the disc to the seat after lapping or cutting on a lathe.
h. Always spot$in the seat and disc after grinding$in.
2,. VALVE PART MAINTENANCE
In addition to the processes used to inspect and repair the seating areas of
valve parts, other types of maintenance should be performed on a
disassembled valve.
The stem bushing should be inspected for wear and damage. )ormally, on a
rising stem valve, the threads of the stem rotate on the threads of the bushing
to open and close the valve. "or this reason, the stem bushing receives a
great amount of wear as the valve is operated. If the bushing threads are
allowed to wear out on a rising stem valve, the valve will no longer close.
-ystem pressure will force it open, and the valve operator will not be able to
close the valve.
Thus, the bushing threads should be carefully checked for wear. If they are
found to be worn, it is best to replace the bushing. to do this, a file, grinder, or
hacksaw may be re:uired, since the bushing is usually tack$welded in place.
After the tack$weld is removed, the bushing can be turned with a wrench and
taken out. The bushing threads are different from the stem threads, but, on a
disassembled valve, the bushing can be replaced by using this method.
If the valve is in place while the bonnet bushing is being replaced, the stem
would be rotated at the same time the bushing is removed and threaded into
the bonnet. *therwise, the stem and bushing threads would bind; this would
damage the threads and prevent the installation of a new bushing.
The valve stem is inspected ne6t. It must be straight. A bent stem can cause
e6cessive and rapid wear to the valve packing. ?ust a slight bend in the stem
can render a valve inoperable, and can prevent the packing from sealing
properly, which would result in leakage.
The stem is placed on a lathe or /$block, as illustrated in "ig. #$%@, where the
total run$out is checked with a dial indicator. The dial indicator is arranged to
so that it is in contact with the stem. As the stem is rotated, the run$out is
indicated on the dial. If the dial remains constant on zero, the stem is straight.
If it is not straight, the dial will indicate the degree of deviation. If the stem is
bent, it must be straightened or replaced.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' = /AL/'- A). /AL/' &AI)T')A)'
0i(, 7--., Ste& Ins5e*tion,
!hile the valve is fully disassembled, all threaded surfaces should be cleaned
thoroughly with a wire brush. The bolts and studs threads should be chased
with a thread chaser.
"inally, the flanges should be carefully inspected. The flanges of both the
valve and the pipe should be cleaned with a wire brush before inspection. A
putty knife may be needed to scrape material that is hard to remove. are
must be taken, however, to avoid making nicks or gauges on the flange
surfaces with the scraper, as that could result in leakage when the valve is
placed back in service.
!hile the valve is out of the system, maintenance can be performed to the
e6terior surfaces. -andblasting and then painting e6ternal surfaces will help
to preserve the valve.
3,. VALVE REASSEMBL/
!hen cleaning and inspection have been completed, the valve is ready to be
reassembled. An important part of reassembly, after all repairs have been
made, is proper lubrication. All moving and threaded parts should be well
lubricated during valve reassembly. &any lubricants, both wet and dry, are
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' %@
available, and the proper type must be used for each surface . The
manufacturerAs instructions should be checked to determine which lubricant is
correct for a particular valve.
The first stem in reassembly is to put the stem through the bonnet, and then
slide the packing gland over the stem 2"ig. #$%%4. Then the stem is carefully
threaded through the yoke bushing until the valve is in the fully open position.
0i(, 7---, Re#sse&%7! of the Ste& #nd P#*+in( G#nd,
A gasket is set on the body seating surface. Then the stem, bonnet, and
packing gland assembly is placed on the valve body. It is important that a new
gasket be used each time a valve is reassembled following maintenance.
0reviously compressed gaskets will not provide a proper seal once they are
removed from the valve.
The body$to$bonnet bolts are set in and tightened evenly to compress the new
gasket uniformly. A cross$tor:ue pattern is used to tighten the body$to$bonnet
bolts. In this type of pattern, one bolt is tightened, and then the bolt opposite
to that bolt is tightened. Then, a bolt ne6t to the first bolt is tightened, and
then the bolt opposite it. The pattern is continued until all bolts are tor:ue to
their proper valves. The valve manufacturerAs manual will indicate the proper
tor:ue valve.
In reassembling a valve, it is important that the disc be kept in the fully open
position. This prevents the disc from being driven into the seat, which could
cause damage to the seating surfaces or bend the valve stem. In addition,
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' %% /AL/'- A). /AL/' &AI)T')A)'
the bonnet must seat s:uarely on the body of the valve as the bonnet bolts
are tor:ue.
After the bonnet is installed, the valve is repacked. The process, shown in
"ig. #$%3. "inally, if the stem bushing is e:uipped with a grease fitting, the
valve stem should be greased.
The valve is now fully reassembled.
0i(, 7--1, P#*+in( # V#)e,
!hen a valve is damaged severely enough to warrant replacement, several
points must be considered in choosing a new one. The replacement valve
must be the same type as the damaged valve and must be rated for the same
kind of service. The flanges on a new valve must be the same size and type
as those of the damaged valve in order to fit with the piping of the system.
The flanges must also have the same face$to$face clearance and hole
alignment.
4,. PARTICULAR MAINTENANCE PROCEDURES
The maintenance procedures discussed thus far concerning valve
disassembly, re$packing, repairing, and reassembly are basically the same for
all types of valves. There are certain procedures, however, that the performed
only on a certain type of valve.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' %3
6,. VALVE PACKING
6,- INTRODUCTION TO PACKING
0acking is a tough rope$like material which is commonly impregnated with a
lubricant. It is used to prevent leaks of li:uids and gases around a valve stem
and bonnet.
+sually, packing is contained in an assembly called a packing gland. "ig. #$%5
shows a typical valve packing gland assembly.
0i(, 7--2, A t75i*# )#)e 5#*+in( (#nd #sse&%7,
To produce a seal around moving parts, packing is cut into rings. These rings
are wrapped around a valve stem. They are then fitted into a cavity in the
packing gland called a stuffing bo6. "ig. #$%7 shows packing rings fitted into a
valve stuffing bo6.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' %5 /AL/'- A). /AL/' &AI)T')A)'
0i(, 7--3, P#*+in( Rin(s 0itted into # V#)e St'ffin( Bo:,
*nce the packing rings have been fitted and seated in a stuffing bo6, they are
compressed by a gland follower. The gland follower causes the packing to put
pressure on a valve stem. This produces a seal. "ig. #$%8 shows packing
being compressed by a gland follower.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' %7
0i(, 7--4, P#*+in( Bein( Co&5"essed %7 # G#nd 0oo$e",
"or packing to work correctly, it must be checked regularly. The packing will need
regular adBustment to take up wear caused by shaft or the opening and
closing of a valve.
7,. PACKING MATERIALS
/alves are Bust one item in which packing is used. )early all machines that
have shafts or stems passing through their casings or housings use packing.
;ecause there are many uses for packing, it is manufactured in a wide range
of materials and sizes shown in "ig. #$%9.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' %8 /AL/'- A). /AL/' &AI)T')A)'
0i(, 7--6, R#n(e of T75i*# V#)e P#*+in( M#te"i#s,
0acking is manufactured from fibrous materials such as fla6, cotton, and
asbestos. 0acking is also made from metals such as lead, aluminum, babbitt,
and plastics like Teflon, nylon and kevlar.
These materials are usually constructed to from a continuous s:uare or round$
shaped strand. The packing is sometimes impregnated with a lubricant like
graphite or mineral oil. "igs. #$%=, #$3@, #$3% A). #$33 below show some
common types of packing construction.
7,- 0IBER PACKING
"iber packing is manufactured in many different forms as shown. Interlocking
braid and braid over braid is very strong. It is suitable for use where there is
high pressure.
-:uare braid and twisted packing is very fle6ible and is usually used on
reciprocating shafts.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' %9
0i(, 7--7, E:#&5es of 0i%e" P#*+in(,
"iber packing is also woven into cloth which may be wrapped or laminated between
layers or rubber, plastic, and graphite
0i(, 7--8, 0i%e" P#*+in( $o)en into Coth,
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' %# /AL/'- A). /AL/' &AI)T')A)'
7,1 METAL PACKING
&etal packing is made in crimped or spiral wound form. It may have a hollow
core. ;ecause of their low melting points, lead and babbitt packing are used
for temperatures below 78@ . Aluminum foil is used for temperatures
above 78@ .
0i(, 7--9, C"i&5ed #nd S5i"# ;o'nd Met# P#*+in(,
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' %<
7,2 PLASTIC PACKING
0lastic and other synthetic packing materials are usually manufactured in
performed C/sC called chevrons and also in solid rings.
0i(, 7-1., E:#&5es of P#sti* P#*+in(,
As previously stated, there are many types of packing materials and many
uses for them. The packing material reference table, shown below, will assist
in the correct selection of packing materials for various applications.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' %= /AL/'- A). /AL/' &AI)T')A)'
T#%e 7--, P#*+in( Refe"en*e T#%e,
"L+I. 0ADI)1
lear water hot or cold$sewage slurries $
calcium brine $ neutral li:uids. &a6imum
temperature 3%3 ".
!hite asbestos or cotton plaited
construction with general service lubricant.
1raphited.
lear hot or cold water $ neutral li:uids.
&a6imum temperature 7@@ ".
-pecial white asbestos plaited construction
with a high temperature lubricant.
1raphited.
Acids$sulfuric, nitric and other acids.
&a6imum temperature 38@ ".
;lue African asbestos plaited construction
with an acid resisting lubricant. 1raphited.
Alkalis$caustic soda$silicate of soda$
sulfates$Draft li:uors$salt brine. &a6imum
temperature 38@ ".
!hite asbestos lattice braid construction
with non$saponifiable 2non$soapy4 lubricant.
1raphited.
"ood products beverages and any li:uid
where non$contamination is the governing
factor. &a6imum temperature %<@ ".
"irst grade asbestos or cotton plaited
construction impregnated with an edible
compound which is colorless, tasteless and
odorless. )on$graphited
-olvents$alcoholAs$chlorinated
hydrocarbons to 38@ ". "uel oils,
kerosene.
!hite asbestos strands plaited or
interwoven construction impregnated with a
solvent resistance lubricant. 1raphited.
!here metallic packing is preferred for cold
or hot water mild alkalis mild acids brine
boiler feed service. &a6imum temperature
78@ ". !here suction pressure e6ceeds
8@ psi.
rinkled lead foil sheets with resilient
asbestos core.
Alkalis and other li:uids with p( factors
above # for temperature =@$78@ ".
Teflon , impregnated white asbestos braid
packing.
Acids weak or concentrated, specifically
those with a p( factor of 7 or less. "or
temperature =@$78@ ".
Teflon , impregnated blue asbestos braid
packing
8,. IN-SERVICE INSPECTION
/alves are inspected while in service to determine if the components function
properly under routine operating conditions. !hen inspecting a valve, it may
be necessary to perform minor adBustments, such as adBusting the packing or
the operator, to keep the valve in good operating condition.
0articular attention should be given to the stuffing bo6 and flanges to check
for leaks in the packing or gaskets. !hen defects are found that cannot be
corrected immediately, they must be reported so that necessary action can be
taken.
9,. REASONS 0OR MAINTENANCE
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 3@
.epending on facility procedures, repair of a valve may be re:uired because
of failure or loss of efficiency.
'fficiency can be lost due to stem leaks, stem binding, improper operator
adBustment, leaking while the disc is closed against the seat, leaks in flange
mating surfaces, or other defects.
/alves are not usually disassembled for periodic maintenance. In most
instances, valves are not taken out of service until a loss of operating
efficiency is noted. *f course, failure of a valve may re:uire a complete
overhaul.
!hen performing maintenance, the manufacturerAs instructions should be
reviewed before proceeding with any disassembly work.
-.,. PACKING REMOVAL
The first step in removing worn or damaged packing from a valve is to lockout
and isolate the valve from all process flow. The ne6t step is to slacken and
remove the gland follower nuts as shown in "ig. #$3% .epending on the type
of valve, the gland follower nuts may be threaded onto dogs, in which case
they may be swung aside.
0i(, 7-1-, G#nd 0oo$e" N'ts %ein( Re&o)ed,
After the gland follower nuts have been removed, the gland follower can be
positioned and wired ne6t to the yoke. If the gland follower is of a split type, it
can be removed completely.
The ne6t step is to remove the packing gland as shown in "ig. #$33. The
packing gland is also positioned and wired ne6t to the gland follower andEor
yoke. In many applications, the packing gland is part of the gland follower.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' 3% /AL/'- A). /AL/' &AI)T')A)'
0i(, 7-11, ;i"in( # P#*+in( G#nd Ne:t to G#nd 0oo$e",
To remove the packing from the valve stuffing bo6, a fle6ible packing e6tractor
is used as shown in "ig. #$35.
0i(, 7-12, 0e:i%e P#*+in( E:t"#*to",
The spiral end of the e6tractor is inserted and screwed into a packing ring.
!hen the e6tractor has been firmly screwed into a packing ring it is then
removed as shown in "ig. #$37. All remaining packing rings are removed in
the same way.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 33
0i(, 7-13, P#*+in( Rin( Bein( Re&o)ed f"o& # )#)e St'ffin( %o:,
--,. PACKING INSTALLATION
--,- MANU0ACTURE O0 VALVE PACKING RINGS
The first step is manufacturing packing rings is to determine the size and
number of packing rings needed to repack a stuffing bo6 and the type of
packing material to be used.
The type of packing material to be used will depend on the type of li:uid or
gas flowing through the piping system.
The size and number of packing rings can be determined by referring to the
manufacturerAs specifications 2information sheet supplied with the valve4.
These are usually kept in the plant maintenance office records. If the
information sheets are not available, it will be necessary to measure the valve
stuffing bo6 to determine the size and number of packing rings.
The packing ring size is determined by measuring the gap between the
stuffing bo6 wall and the stem outside diameter using a rule, as shown in "ig.
#$38 or inside calipers. The measurement should be recorded so that it is not
forgotten.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' 35 /AL/'- A). /AL/' &AI)T')A)'
0i(, 7-14, Me#s'"in( # V#)e St'ffin( Bo: to Dete"&ine P#*+in( si<e,
The ne6t step is to determine the number of packing rings needed. This is
done by measuring the depth of the stuffing bo6 using a fle6ible rule. If there
is limited space and a rule cannot be used, the measurement can be taken by
inserting a piece of wire into the stuffing bo6. +se your thumb to mark the
depth as shown in "ig. #$39. !hen the wire has been removed, the distance
from your thumb to the end of the wire can be measured with a rule. This
measurement should also be recorded so that it is not forgotten.
0i(, 7-16, Me#s'"in( the De5th of # V#)e St'ffin( Bo:,
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 37
E=AMPLE O0 RECORDED MEASUREMENTS
-ize of packing, width %E7C
.epth of stuffing bo6 %$8E%9C
.etermine the size and number of packing rings as follows>
-ize, width of packing ring F %E7C
)umber of 0acking ,ings F 8
To repack the stuffing bo6, 8 packing rings need to be cut from %E7C thick
packing.
--,1 MANU0ACTURE BUTT JOINT PACKING RINGS
After the size and number of packing rings re:uired to repack a valve has
been determined, select the correct packing material. This will be determined
by the type of li:uid or gas flowing through the piping system.
!hen the correct packing material has been selected, the ne6t step is to
manufacture the packing rings.
0acking rings are cut on a mandrel. This is a piece of round bar which is the
same diameter as the valve stem. The packing material is wrapped around
the mandrel the correct number of times, i.e.> 8 times if 8 packing rings are
re:uired.
The packing material is held in position on the mandrel. A sharp knife is then
used to cut the packing material lengthwise as shown in "ig. #$3#.
The packing material must be cut in a straight line along the mandrel.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' 38 /AL/'- A). /AL/' &AI)T')A)'
Number of Packing Rings =
Depth of Stuffing Box
Size of Packing
Number of Packing Rings =
1- 5 / 1!
"!
0i(, 7-17, C'ttin( B'tt Joint P#*+in( Rin(s on # M#nd"e,
--,2 MANU0ACTURE SKIVE >34 ANGLE? JOINT PACKING RINGS
After the size and number of packing rings re:uired to repack a pump has
been determined, select the correct packing material. This will be determined
by the type of li:uid or gas flowing through the piping system.
!hen the correct packing material has been selected, the ne6t step is to
manufacture the packing rings.
0acking rings are cut on a mandrel. This is a piece of round bar which is the
same diameter as the valve stem. The packing material is wrapped around
the mandrel the correct number of time, i.e., 8 times if 8 packing rings are
re:uired.
The packing material is held in position on the mandrel. A sharp knife is then
used to cut the packing material lengthwise at an angle of 78 as shown in
"ig. #$3<.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 39
0i(, 7-18, C'ttin( A S+i)e >34@ An(e? Joint P#*+in( Rin(s on # M#nd"e,
--,3 INSTALL PACKING
;efore packing can be installed in a valve packing gland assembly, the
stuffing bo6, stem and packing gland should be cleaned using a solvent.
If dirt or sand is allowed to get into the stuffing bo6, it will cause damage to the
stem and packing. After cleaning, the stem and packing gland should be
inspected for damage and wear.
To install the packing, a packing ring is placed around the stem as shown in
"ig. #$3=.
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' 3# /AL/'- A). /AL/' &AI)T')A)'
0i(, 7-19, A P#*+in( Rin( %ein( 5#*ed #"o'nd # V#)e Ste&,
The packing ring is then pushed down and seated in the bottom of the stuffing
bo6 using the packing gland.
*n larger valves, a split bushing can be used to install and seat the packing
rings. "ig. #$5@ shows a packing gland being used to install and seat a
packing ring.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 3<
7-2., A P#*+in( (#nd Bein( 'sed to inst# #nd se#t # P#*+in( Rin(,
!hen the first packing ring has been seated correctly, the packing gland is
removed from the stuffing bo6.
The remaining packing glands can be installed and seated using the same
steps. ;ut before doing so, they must be placed so that their butted ends face
a different direction 2staggered4 from that of the previous packing ring.
If the butted ends of all the packing rings were placed in a straight line, the
li:uid or gas flowing through the valve would leak through the gap.E
"ig. #$5% shows an alternative method of staggering packing rings.
0i(, 7-2-, An(e Method of St#((e"in( P#*+in( Rin(s,>B'tted Ends #"e
St#((e"ed #t 9.@?
&'(A)IAL &AI)T')A)' *+,-' A./A)'. *+,-'
L'--*) # 0A1' 3= /AL/'- A). /AL/' &AI)T')A)'
0i(, 7-21, Ate"n#ti)e Method of St#((e"in( P#*+in( Rin(s,
!hen the last packing ring has been installed and seated, the packing gland,
gland follower dogs, and gland follower are replaced.
The gland follower nuts are then nipped down e:ually, while the valve hand
wheel is turned. This is done so that the packing is not over compressed so
as to cause the stem a seize.
A./A)'. *+,-' &'(A)IAL &AI)T')A)' *+,-'
/AL/'- A). /AL/' &AI)T')A)' L'--*) # 0A1' 5@