Original 51848 JW Valve Brochure 24pp Updatenew

8/3/2019 Original 51848 JW Valve Brochure 24pp Updatenew

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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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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


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


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


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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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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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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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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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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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


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.


15/24

Valve seating


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


16/24

PTFE Chevron & KVSP


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


17/24

Spring energised PTFE lip seals


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


18/24

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


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


19/24

Specialised metal components


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


20/24

Tension control bolting


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.


21/24

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


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.


22/24

Services


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


23/24

Technical guides & data sheets


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


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


World-leadingsealingtechnology

Highintegrityproductsforsafety,environmental&revenueprotection

RGD-resistantelastomersqualifiedtoNorsok M-710

Globalstockholding&support

Proventrackrecord

Issue 8

Compression Packings Guide


The comprehensive guide to compression packings for

Pumps Valves Hatch lids Crucible lids Furnace doors

Gland sealing duties

Hydraulic Sealing Guide


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


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


24/24

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


James Walker BrasilTel: +55 21 2220 2152Fax: +55 21 253 11704


James Walker China

Tel: +86 21 6876 9351Fax: +86 21 6876 9352


James Walker Deutschland

Tel: +49 (0)40 386 0810Fax: +49 (0)40 389 3230


James Walker FranceTel: +33 (0)437 497 480Fax: +33 (0)437 497 483


James Walker Iberica

Tel: +34 94 447 0099Fax: +34 94 447 1077


James Walker Ireland

Tel: +353 (0)21 432 3626Fax: +353 (0)21 432 3623


James Walker ItalianaTel: +39 02 257 8308Fax: +39 02 263 00487


James Walker Mfg Co. (USA)

Tel: +1 708 754 4020Fax: +1 708 754 4058


James Walker New ZealandTel: +64 (0)9 272 1599Fax: +64 (0)9 272 3061


James Walker Norge

Tel: +47 22 706 800Fax: +47 22 706 801


James Walker Oil & Gas (USA)

Tel: +1 281 875 0002Fax: +1 281 875 0188


James Walker SingaporeTel: +65 6777 9896Fax: +65 6777 6102


James Walker South Africa

Tel: +27 (0)31 304 0770Fax: +27 (0)31 304 0791


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


Documents

Original 51848 JW Valve Brochure 24pp Updatenew