Mejora en El Desempeño de Empaques para Válvulas

Valve Packing Performance Improvement
Sealing Technology & Plant Leakage Reduction Series
SED
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Technical Report
Valve Packing Performance

Improvement
Sealing Technology & Plant Leakage Reduction
Series
1000923
Final Report, March 2002
EPRI Project Manager

M. Bridges
EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
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CITATIONS
This report was prepared by
Dominion Engineering, Inc.
6862 Elm Street
McLean, VA 22101
Principal Authors
S. Hunt, Dominion Engineering, Inc.
K. Hart, PPL Electric Utilities Corp.
This report describes research sponsored by EPRI.
This report is a corporate document that should be cited in the literature in the following manner:
Valve Packing Performance Improvement: Sealing Technology & Plant Leakage Reduction
Series, EPRI, Palo Alto, CA: 2002. 1000923.
iii
REPORT SUMMARY
Valve Packing Performance Improvement is the seventh in a series of training modules

addressing leakage at nuclear power plants. The first six modules in this series address:
Leakage management programs
Assembling bolted joints with spiral-wound gaskets
Preload requirements for bolted joints with spiral-wound gaskets
Lube oil system leakage mitigation
Leakage reduction from threaded joints
Leakage reduction from bolted joints with sheet gaskets
Background
Leakage from valve packing was identified as a major concern by participants in the EPRI Fluid
Sealing Technology Program Working Group. This group has provided the technical guidance
for research into the causes of, and solutions to, valve packing leakage.
Objectives
To provide maintenance personnel, work planners, engineers, quality control (QC) personnel,
and plant management with an understanding of the causes of leakage from valve packing
To provide maintenance personnel, work planners, engineers, QC personnel, and plant

management with alternative approaches available to reduce this leakage
To develop cost-effective, plant-specific programs to reduce leakage from these joints
Note: Because many different valve designs and conditions are encountered in the field, it is
recognized that a guide of this type cannot cover all situations. Users must work closely with
experienced and qualified packing suppliers to select and apply the best products for difficult
applications.
Approach
EPRI Fluid Sealing Technology Program documents are provided in two parts. The first part is a
technical guide that is directed toward engineers, craft supervisors, and trainers. This technical
guide provides an in-depth review of the causes of leakage and the basis for the EPRIrecommended approach to reducing valve packing leaks. The second part consists of training
materials including viewgraphs for classroom instruction and information on the use of a Valve
Packing Performance Demonstration Unit to demonstrate the principles presented in the
classroom.
v
Results
Upon completion of the training:
Engineers should be prepared to work with valve packing suppliers to select the best products
for each application, to update plant maintenance procedures to reflect the latest knowledge,
and to assess the root cause of leaks from valve packing.
Work planners should be able to provide better information in work packages.
Maintenance technicians should have a better understanding of the key factors that led to
high-integrity packing and how to apply this knowledge in the field.
QC personnel should have the knowledge to determine which of the assembly practices
warrant the most attention.
Plant management should have a better overall perspective of issues associated with leakage
from valve packing.
EPRI Perspective
EPRI views this series of reports pertaining to plant leakage reduction as an important and
needed contribution to the state of the art with respect to plant maintenance practices and
operation and maintenance (O&M) cost reduction. Because mitigation of leakage from valve
packing is important to supporting many plant applications, this document within the series is of
significant potential benefit to members concerned with improving plant safety, operability, and
availability, while reducing associated O&M costs.
Keywords
Maintenance
Leakage
Valves
Valve packing
Packing
Live load
vi
EPRI Licensed Material
PREFACE
In 1995, EPRI initiated a training program to help utilities reduce leakage from bolted joints with
spiral-wound gaskets. The current version of these training materials is reported in EPRI TR111472, Assembling Bolted Connections Using Spiral-Wound Gaskets [11]. This training
consists of classroom instruction in the fundamentals of gasketed joints and hands-on instruction
on an EPRI-patented Bolting Performance Demonstration Unit. As of June 2001, this EPRI
training program had been conducted at more than 30 nuclear plants and also at several fossil
electric plants, government facilities, and industrial plants.
In 1998, the leakage reduction program was expanded to cover other aspects of external leakage
from piping systems and components at nuclear plants. This work is coordinated by a utility
Fluid Sealing Technology Program working group. Current documents published under this
program cover:
Leakage management programs
Assembling bolted joints with spiral-wound gaskets
Preload requirements for bolted joints with spiral-wound gaskets
Lube oil system leakage mitigation
Leakage reduction from threaded joints
Leakage reduction from bolted joints with sheet gaskets
This document describes the results of work to determine the causes of leakage from valve
packing and cost-effective solutions to this leakage. This work included the following activities:
Identification of the types of valve packing available
Identification of the causes of valve packing leakage
Development of a program to reduce valve packing leakage
Preparation of training materials, including a Valve Packing Performance Demonstration

Unit, to demonstrate the key factors required to develop high valve packing integrity
vii
CONTENTS
1 BACKGROUND......................................................................................................................1-1
1.1
Objective ......................................................................................................................1-1
1.2
Target Audience ..........................................................................................................1-1
1.3
Relationship to Existing Plant Procedures ...................................................................1-2
1.4
Valve Packing Performance Demonstration Unit.........................................................1-2
1.5
Summary .....................................................................................................................1-3
2 REVIEW OF VALVE PACKING CONCEPTS ........................................................................2-1

2.1
Alternative Methods for Sealing Valve Stems..............................................................2-1
2.2
Valve Packing Concepts ..............................................................................................2-2
2.3
Summary .....................................................................................................................2-4
3 VALVE PACKING LEAKAGE EXPERIENCE........................................................................3-1

3.1
Boric Acid Corrosion Guidebook..................................................................................3-1
3.2
Review of Plant Maintenance Records ........................................................................3-2
3.3
NUREG/CR-6582 ........................................................................................................3-4
3.4
Summary .....................................................................................................................3-6
4 VALVE PACKING CONFIGURATIONS AND PRODUCTS...................................................4-1

4.1
Valve Packing Technology Evolution...........................................................................4-1
4.1.1
Braided Asbestos Packing (Figure 4-1.a) ...........................................................4-3
4.1.2
Braided Non-Asbestos Packing (Figure 4-1.b)....................................................4-3
4.1.3
Die-Formed Flexible Graphite Packing With Braid End Rings

(Figure 4-1.c).......................................................................................................4-4
4.1.4
Engineered Die-Formed Flexible Graphite Packing System (Figure 4-1.d) ........4-5
4.2
Components in Die-Formed Flexible Graphite Packing System..................................4-5
4.2.1
Die-Formed Flexible Graphite Packing Rings .....................................................4-6
4.2.2
Anti-Extrusion Rings..........................................................................................4-10
4.2.3
Spacers .............................................................................................................4-11
ix
4.2.4
Bushings ...........................................................................................................4-12
4.2.5
Lantern Rings....................................................................................................4-12
4.2.6
Packing Washers ..............................................................................................4-12
4.2.7
Cushion Rings...................................................................................................4-13
4.2.8
Junk Rings ........................................................................................................4-13
4.2.9
Gland Bolting and Hardened Steel Washers ....................................................4-13
4.2.10
4.3
Live Loading ..................................................................................................4-14
Components in Braid Ring Packing System ..............................................................4-15
4.3.1
Braided Asbestos ..............................................................................................4-15
4.3.2
Braided PTFE....................................................................................................4-15
4.3.3
Braided Graphite Fiber Yarn .............................................................................4-16
4.3.4
Braided Carbon Fiber Yarn ...............................................................................4-16
4.3.5
Braided Flexible Graphite Tape ........................................................................4-16
4.4
Commercial Products.................................................................................................4-16
4.5
Summary ...................................................................................................................4-19
5 CAUSES OF VALVE PACKING LEAKS ...............................................................................5-1

5.1
Low Gland Stress ........................................................................................................5-1
5.2
Packing Consolidation .................................................................................................5-2
5.3
Dimensions and Clearances ........................................................................................5-5
5.4
Stem and Stuffing Box Surface Finish .........................................................................5-6
5.5
Stem and Stuffing Box Corrosion.................................................................................5-7
5.6
Stem Misalignment ......................................................................................................5-8
5.7
Stem Thermal Taper ..................................................................................................5-10
5.8
Product Misapplication...............................................................................................5-11
5.9
Aging..........................................................................................................................5-13
5.10
Functional Failure Due to Excessive Friction ........................................................5-13
5.11
Summary...............................................................................................................5-14
6 SELECTING PACKING CONFIGURATIONS AND PRODUCTS ..........................................6-1
6.1
Overview of Packing Options.......................................................................................6-1
6.2
Packing Coding System...............................................................................................6-2
6.3
Suggested Packing Configurations..............................................................................6-2
6.3.1
Basic Die-Formed Flexible Graphite Packing (BX000XSW) ...............................6-2
6.3.2
Low-Friction Packing...........................................................................................6-3
6.3.3
All Braid Non-Asbestos Packing (BZZZZSW) .....................................................6-4
6.4
Other Packing Configurations ......................................................................................6-4
6.5
Inventory Optimization .................................................................................................6-4
6.6
Evaluating Packing Suppliers and Products ................................................................6-5
6.6.1
Vendor Support ...................................................................................................6-5
6.6.2
Product Qualification Testing ..............................................................................6-5
6.7
Summary .....................................................................................................................6-5
7 GLAND PRELOAD.................................................................................................................7-1
7.1
Gland Preload Stress and Required Sealing Force .....................................................7-1
7.2
Achieving Preload by Torquing ....................................................................................7-2
7.2.1
Determining Appropriate Torque.........................................................................7-2
7.2.2
Ensuring That Applied Torque Results in the Desired Preload...........................7-3
7.2.3
Providing for Consolidation .................................................................................7-5
7.3
Stem Friction................................................................................................................7-5
7.4
Live Loading ................................................................................................................7-7
7.5
Diagnostics ................................................................................................................7-11
7.6
Gland Design .............................................................................................................7-12
7.6.1
Gland and Follower Design One- vs. Two-Piece ...........................................7-12
7.6.2
Gland Length.....................................................................................................7-13
7.6.3
Gland-to-Stuffing Box Clearance ......................................................................7-13
7.6.4
Gland Machining Practices ...............................................................................7-14
7.6.5
Gland Materials .................................................................................................7-14
7.7
Summary ...................................................................................................................7-14
8 DEMONSTRATIONS USING VALVE PACKING PERFORMANCE

DEMONSTRATION UNIT..........................................................................................................8-1
8.1
Valve Packing Performance Demonstration Unit.........................................................8-1
8.2
Initial EPRI VPDU Experiments ...................................................................................8-4
8.3
Summary .....................................................................................................................8-7
9 VALVE PACKING INSTALLATION PROCEDURES.............................................................9-1

9.1
Valve Packing Procedure ............................................................................................9-1
9.1.1
Remove Old Packing ..........................................................................................9-1
9.1.2
Inspect Valve.......................................................................................................9-2
9.1.3
Prepare Bolting ...................................................................................................9-2
xi
9.1.4
Obtain New Packing Components ......................................................................9-3
9.1.5
Install Packing .....................................................................................................9-3
9.1.6
Consolidate Packing ...........................................................................................9-4
9.1.7
Apply Live Loading if Used..................................................................................9-4
9.1.8
Periodic Retorquing.............................................................................................9-5
9.2
Overview of Key Installation Steps ..............................................................................9-6
9.3
Valve Packing Tips ......................................................................................................9-6
9.4
Summary .....................................................................................................................9-8
10 VALVE PACKING IMPROVEMENT PROGRAMS.............................................................10-1

10.1
Establishing Program Goals..................................................................................10-1
10.2
Selecting a Packing Supplier ................................................................................10-2
10.3
Selecting a Packing Product Strategy...................................................................10-2
10.4
Creating a Database of All Valves ........................................................................10-3
10.5
Prioritizing Valves for Rework ...............................................................................10-3
10.6
Providing Training .................................................................................................10-4
10.7
Work Planning.......................................................................................................10-5
10.8
Technical Support .................................................................................................10-5
10.9
Monitoring and Periodic Retorquing......................................................................10-5
10.10
Root Cause Analysis and Feedback .....................................................................10-8
10.11
Summary...............................................................................................................10-8
11 OVERVIEW.........................................................................................................................11-1
11.1
Technical Fundamentals .......................................................................................11-1
11.2
Programmatic Fundamentals ................................................................................11-2
12 REFERENCES ...................................................................................................................12-1
A TRAINING SLIDES ............................................................................................................... A-1
B SAMPLE VALVE PACKING SURVEILLANCE AND RETORQUING PROGRAM .............. B-1
xii
LIST OF FIGURES
Figure 1-1 Valve Packing Performance Demonstration Unit .....................................................1-2
Figure 2-1 Alternative Methods for Sealing Valve Stems ..........................................................2-1
Figure 2-2 Idealized Model of Valve Packing.............................................................................2-3
Figure 3-1 Sources of Leaks Causing Reported Boric Acid Corrosion ......................................3-2
Figure 3-2 Recent EPRI Analysis of Sources of Leaks at Six Plants.........................................3-4
Figure 3-3 Sources of Leaks per NUREG/CR-6582 ..................................................................3-5
Figure 3-4 Number of Valve Packing Leaks per Year per NUREG/CR-6582 ............................3-6
Figure 4-1 Evolution of Valve Packing Systems ........................................................................4-2
Figure 4-2 Typical Component Parts of Engineered Die-Formed Packing System ...................4-6
Figure 4-3 Design and Performance of Wedge-Type Packing ..................................................4-9
Figure 4-4 Damage to Graphite Spacer Caused by Angled Surface at Bottom of Stuffing
Box ...................................................................................................................................4-13
Figure 4-5 Typical High-Pressure Valve Gland Bolting Without Live Load ..............................4-14
Figure 5-1 Consolidation of Die-Formed Flexible Graphite Packing ..........................................5-2
Figure 5-2 Packing Consolidation ..............................................................................................5-3
Figure 5-3 Effect of Consolidation on Gland Load .....................................................................5-4
Figure 5-4 Running Tolerances and Clearances (MSS SP-120) ...............................................5-5
Figure 5-5 Stuffing Box Tolerances (MSS SP-120) ...................................................................5-6
Figure 5-6 Stem Tolerances (MSS SP-120) ..............................................................................5-6
Figure 5-7 Stem Corrosion Test Fixture (MSS SP-121) ............................................................5-8
Figure 5-8 Typical Effects of Stem Misalignment.......................................................................5-9
Figure 5-9 Use of Bushings to Mitigate Stem Misalignment ....................................................5-10
Figure 5-10 Effect of Stem Thermal Taper on Packing Consolidation.....................................5-11
Figure 5-11 Decomposition Rate of PTFE at Elevated Temperature.......................................5-13
Figure 7-1 Galling on Follower Caused by Lack of Hardened Steel Washers ...........................7-4
Figure 7-2 Galling of Soft Steel Washers Provided by Valve Supplier ......................................7-4
Figure 7-3 Live Loading Using Belleville Washers.....................................................................7-7
Figure 7-4 Alternative Live Loading Configurations ...................................................................7-8
Figure 7-5 Effect of Live Loading on Valve Gland Stress ..........................................................7-9
Figure 7-6 Live Loading Spring Packs .....................................................................................7-10
Figure 7-7 Potential Gland Follower Improvements.................................................................7-13
Figure 8-1 Valve Packing Performance Demonstration Unit (VPDU) ........................................8-2
xiii
Figure 8-2 VPDU Packing Assembly and Valve Stems .............................................................8-3

Figure 9-1 Summary of Key Valve Packing Points ....................................................................9-6
Figure 9-2 Use of Shims to Ensure Gland Alignment ................................................................9-8
xiv
LIST OF TABLES
Table 3-1 Evaluation of Leakage-Related Work Orders for Two Sites (19951999) ................3-3
Table 4-1 Valve Packing Products Commercial Products Survey ........................................4-17
Table 8-1 Initial VPDU Experimental Results ............................................................................8-6
Table 8-2 Summary of Initial VPDU Experimental Results ........................................................8-7
Table 10-1 Valve Retorque Schedule Used at BWR Plant With Reported Small Number
of Leaks............................................................................................................................10-7
Table B-1 Sample Valve Packing Surveillance and Repacking Program (BWR Plant) ........... B-2
xv
BACKGROUND
This section provides background information regarding training

objectives, target audience, and the basis for focusing attention on leakage
from valve packing.
2
Icons
represent the
accompanying
course slides,
which can be
found in
Appendix A.
1.1
Objective
The objective of this training is to help nuclear plant personnel reduce the
number and severity of leaks from valve packing. This objective will be
accomplished by providing a better understanding of the key factors that
contribute to valve packing integrity. These factors include:
How valve packing works
Types of packing available and where they should be used
Required packing gland loads
Role of consolidation in long-term packing performance
Importance of live loading for valves in cyclic duty applications
Major causes of packing leaks
Valve packing installation guidelines
The training also provides hands-on experiments to reinforce the

understanding of key factors that result in high valve packing integrity.
1.2
Target Audience
The training is directed toward a broad audience of plant maintenance

technicians, work planners, maintenance engineers, systems engineers,
and quality control (QC) personnel. The training is intended to help these
individuals reduce leakage from valve packing through improved
knowledge of the factors that contribute to valve packing integrity. The
training can also serve as a useful refresher for plant engineers responsible
for preparing procedures and for troubleshooting leaking equipment.
1-1

Background
1.3
Relationship to Existing Plant Procedures
The training is not intended to supersede existing plant procedures, but

rather to better support them. Personnel should continue to follow
approved plant procedures until those procedures have been changed.
1.4
Valve Packing Performance Demonstration Unit
Experience with previous EPRI leakage reduction training programs has

confirmed the importance of providing an appropriate level of hands-on
training to reinforce fundamentals. This is especially important in a mature
industry where personnel are often reluctant to change from past practices
unless the limitations of these practices, and the benefits of the proposed
change, can be clearly demonstrated.
A Valve Packing Performance Demonstration Unit (VPDU) was
developed to demonstrate key valve packing principles. The VPDU is
shown in Figure 1-1. Section 8 of this report provides a more complete
description of the VPDU and the results of the initial experiments
performed using the VPDU.
Figure 1-1
1-2

Background
1.5
Summary
The objective of this training is to assist plants in reducing leaks from

valve packing by providing a better understanding of the factors that
contribute to high joint integrity and a suggested packing procedure.
Training is directed toward engineers, maintenance technicians, and

work planners.
Information presented must not supersede plant procedures but can be

used to improve procedures.
Classroom instruction is supplemented by experiments using the

VPDU.
1-3
REVIEW OF VALVE PACKING CONCEPTS
This section briefly reviews several methods that can be used to seal valve
stems and describes how valve packing functions to produce a seal.
5
2.1
As shown in Figure 2-1, valve stems can be packed or hermetically sealed.

Packing can include packing rings, chevron or V packing, and o-ring
seals. Stems can be hermetically sealed by metallic bellows or
diaphragms.
Alternative Methods for Sealing Valve Stems
Figure 2-1
Alternative Methods for Sealing Valve Stems [1]
2-1

Review of Valve Packing Concepts
Packing rings are used for most applications in nuclear plants. Rings of
flexible packing material are inserted into the annulus between the valve
stem and stuffing box and are then compressed axially by a gland
follower. The axial load on the flexible packing forces the packing to
expand outward and to create radial seals to the stem and stuffing box.
Chevron, or V packing, is designed to be installed using the same
approach as packing rings, but to produce higher radial forces, and
theoretically a better seal, for the same amount of axial force.
O-rings provide low leakage and low friction, but the elastomeric
materials used in o-rings typically have a limited temperature capability
and often contain chemicals such as halogens that preclude their use in
many nuclear applications. However, o-rings are used successfully in
many instrument and pneumatic system applications.
Metallic bellows and diaphragms produce a hermetic seal that results in
the lowest achievable leak rates. However, metal diaphragms are limited
to low-stroke applications, and it is difficult to achieve a long stroke with
high system pressures using metallic bellows.
The majority of valves in commercial nuclear plants are sealed by packing
rings. This relatively low-cost solution can accommodate large valve
strokes at high system temperatures and pressures. In addition, when
properly matched to the application and properly installed, packing rings
will provide a reliable low-leakage seal. This report focuses on commonly
encountered packing ring valve stem seals.
7
2.2
Valve Packing Concepts
Figure 2-2 shows how packing rings function to seal a valve:
Packing is inserted between the valve stem and the stuffing box in the
valve bonnet
An axial preload force is applied to the packing by a gland that is in

turn loaded by torquing the gland nuts
The axial force on the packing causes the packing to expand both
inward and outward, creating radial seals at both the stem and the
stuffing box
2-2

Figure 2-2
Idealized Model of Valve Packing
Several important technical issues can affect packing performance. These

include:
The packing should ideally include rings of die-formed flexible

graphite material that provide a tighter seal than most braided
materials.
Braided materials that are intended for use as seals, rather than only as
anti-extrusion rings, include blocking materials to fill up the voids
between the braided strands. Some examples of blocking materials are
graphite, polytetrafluoroethylene (PTFE), and lubricants.
Because packing materials are flexible and can flow under load,
provisions must be made to keep the material from extruding between
the stem and gland, between the gland and the stuffing box, and
between the stem and bonnet. Many braid-type packing materials can
accommodate the normal clearances between the stem and gland and
between the gland and stuffing box without adding anti-extrusion
rings. However, die-formed flexible graphite has less strength and
typically requires the addition of anti-extrusion rings.
Because all packing materials contain voids, they must be properly

compressed (consolidated) during installation. If the material is not
properly compressed during assembly, the axial load on the gland will
decrease as the valve is stroked.
2-3

The axial load on the gland decreases over time due to wear, or loss of
braid ring blocking material. Ideally, there should be some compliance
in the packing that can accommodate small amounts of consolidation,
wear, stem imperfections, and stem thermal taper.
Loss of gland force due to service-induced packing consolidation,

wear, or loss of blocking material can be compensated for by
periodically retorquing the packing or by installing Belleville spring
washers between the gland follower and gland nuts.
The radial force between the packing and valve stem results in friction
that must be overcome during valve operation. High axial preload
forces, large depths of packing in the stuffing box, and high-friction
packing materials all contribute to high packing friction.
2.3
Summary
Most valve stems in nuclear plants are sealed by packing rings.
When packing rings are loaded axially by a gland, the packing material
expands both inward and outward to develop radial seals at the valve
stem and the stuffing box.
Packing should ideally include die-formed flexible graphite rings with

inherently low leakage relative to most braided packing.
Packing must be properly consolidated during assembly to prevent an

abnormally high rate of loss of axial force during service.
Packing should be retorqued periodically to compensate for small

amounts of service-induced consolidation and wear.
2-4
VALVE PACKING LEAKAGE EXPERIENCE
This section briefly reviews industry experience with leakage from valve
packing. The description is brief because valve packing leakage represents
an ongoing source of significant operation and maintenance (O&M)
expenditures at most plants and has been described at length in previous
Sealing Technology & Plant Leakage Reduction Series reports.
3.1
Boric Acid Corrosion Guidebook
EPRI TR-104748, Boric Acid Corrosion Guidebook [2], includes a survey

of the causes of boric acid leakage incidents reported before the summer
of 1994. Sources for the information include Nuclear Power Experience
reports, U.S. Nuclear Regulatory Commission (NUREG) reports, U.S.
Nuclear Regulatory Commission (NRC) Information Notices, NRC
Inspection and Enforcement Bulletins, NRC Generic Letters, and NRC
Public Documents Room files. Figure 3-1, excerpted from the Boric Acid
Corrosion Guidebook [2], shows that valve packing leaks represented
approximately 20% of the identified sources. This was the second leading
cause of leaks behind gaskets that comprised approximately 45% of the
total identified sources. A 2001 revision to this report shows similar
conclusions [3].
3-1

Valve Packing Leakage Experience
Figure 3-1
Sources of Leaks Causing Reported Boric Acid Corrosion [2]
3.2
10
Review of Plant Maintenance Records
As part of the Fluid Sealing Technology Program, EPRI visited several

sites to collect information regarding the source of leakage-related
maintenance work orders. Table 3-1 shows the total number of leakagerelated work orders at two plant sites over the five-year period 19951999,
the number of work orders that indicated valve packing as the source of
the leaks, and the percentage of work orders that related to valve packing.
These data confirm that valve packing remains a major source of leakagerelated work orders in terms of absolute numbers and percentage of total
leaks.
3-2

Table 3-1
Evaluation of Leakage-Related Work Orders for Two Sites
(19951999) [3]
Source of
Leak
Total
WO's
Total
WO's
Plant A
Plant B
Average
WO's
Percent
Average WO
Man-Hours for
Plant B
per Year
per Unit
Flanged Joints
and Gaskets
850
189
69
23%
32
Pipe and Tube

Fittings
500
359
57
19%
31
Valve Packing
663
563
82
27%
16
Seals
302
220
35
12%
24
Other
263
620
59
20%
69
Total
2,578
1,951
302
100%
38*
Valve Packing Was Single Largest

Source of Leaks From
1995 Through 1999
*This total is generated from more information than is presented in this table.
3-3

11
Recent analysis by EPRI of the source of leaks at six plants is shown in

Figure 3-2. These data indicate that valve packing is the single largest
identifiable source of leaks.
Figure 3-2
Recent EPRI Analysis of Sources of Leaks at Six Plants
12
13
3.3
NUREG/CR-6582
The Idaho National Engineering and Environmental Laboratory (INEL)

performed a study in 1997 to determine the causes of primary system leaks
reported to the NRC via Licensee Event Reports from 1985 through the
third quarter of 1996 [4]. This includes leakage events that occurred
during hot shutdown, hot standby, startup, and power operation, except for
those through steam generator tubes. Figure 3-3, excerpted from this
study, shows that valve packing was one of the two main reportable causes
of leaks.
3-4

Figure 3-3
Sources of Leaks per NUREG/CR-6582 [4]
Of the 199 reportable leak events during the study period, approximately
60% (121 events) occurred during the first four years and the remaining
40% occurred during the last eight years. One reason for the significantly
lower rate over the last eight years was the elimination of reportable
leakage from valve packing, illustrated in Figure 3-4, which is also
excerpted from the INEL report. However, some primary system valve
packing leaks have not been included in the INEL survey report.
3-5

Figure 3-4
Number of Valve Packing Leaks per Year per NUREG/CR-6582 [4]
3.4
Summary
Valve packing has been a major source of leakage in pressurized water

reactor (PWR) plant primary systems.
Recent operating experience at six plants visited by EPRI has shown

that valve packing represents a significant percentage of the total
recorded leaks at these plants.
A study conducted by INEL for the NRC in 1997 showed that valve
packing was a major source of primary system leakage prior to
approximately 1992. Since that time, significant progress appears to
have been made in reducing leakage from primary system valves.
3-6
VALVE PACKING CONFIGURATIONS AND

PRODUCTS
This section briefly describes the evolution of valve packing and the basic
valve packing configurations and products in widespread use.
15
4.1
Valve Packing Technology Evolution
Valve packing has evolved significantly over the past thirty years. Several
key stages in this evolution are illustrated in Figure 4-1. A review of the
evolutionary stages provides an overview of how packing designs were
changed to improve performance.
4-1

Valve Packing Configurations and Products
Figure 4-1
Evolution of Valve Packing Systems
The evolution of packing designs was gradual, with several different types
of packing commonly in use at any point in time. With the exception of
the braided asbestos packing in Figure 4-1.a, all of these configurations
are used to some extent in plants today.
4-2

16
4.1.1 Braided Asbestos Packing (Figure 4-1.a)

Until the mid-1970s, braided asbestos was the most widely used valve
packing product. It was not perfect, but users were willing to accept and
work around its limitations. The main limitations were poor packing life
and the need for periodic retorquing of gland bolts. These limitations were
accommodated by periodic retorquing, periodic repacking, use of
improved blocking materials,1 and use of double sets of packing with a
leakoff port to monitor for and collect leakage from the primary seal. A
main source of problems was that many packing rings were typically used
on the theory that the greater the length of packing, the better the seal.
Beginning in the mid-1970s, the potential health hazards of asbestos
became better known and became an increasingly significant limitation.
In the 1970s, Atomic Energy of Canada Ltd. (AECL), at their Chalk River
Nuclear Laboratories in Chalk River, Ontario, Canada, began researching
problems associated with leakage from asbestos packing. The incentive for
this research was that the Canadian Deuterium Uranium reactors use
heavy water as a primary system coolant, and leakage of this coolant
was costly. The AECL research increased the understanding of asbestos
packing and highlighted the value of live loading packing with Belleville
washers to compensate for volume loss and consolidation that occurs over
time due to stroking and loss of blocking material (see Section 5 of this
report for a further description of the causes of consolidation). This effort
also resulted in increased use of double-packed valves with monitored
leakoff ports.
16
4.1.2 Braided Non-Asbestos Packing (Figure 4-1.b)

Starting in the mid-1970s, interest in replacing the potentially hazardous
asbestos led to the search for asbestos replacements. The main alternatives
at this point were braided packing woven from graphite, PTFE, or other
fibers. These materials could easily be substituted for the original asbestos
packing. Braided PTFE packing could be used for low-temperature water
applications. Braided graphite could be used for higher temperature
applications and where PTFE was not acceptable due to its potential to
cause cracking of certain corrosion-resistant materials.
Braided graphite, PTFE, and other fiber-type packing rings worked well
for many applications, and are still used in some lower temperature and
pressure nuclear plant applications. However, the braided materials remain
prone to consolidation and loss of blocking material over time. These
1
Blocking material is used to fill in gaps between the fiber strands in braided packing
and thereby produces a better seal for a given gland pressure. Graphite, PTFE, and
lubricants are examples of blocking materials. If low-friction materials are used for
blocking, then the valve stem friction forces can also be reduced.
4-3

factors lead to the need for periodic retorquing, especially for applications
that involve significant valve stroking. Consolidation during operation was
partially addressed by reducing the number of packing rings to four to five
so that all rings would be more uniformly compressed.
17
4.1.3 Die-Formed Flexible Graphite Packing With Braid End

Rings (Figure 4-1.c)
In the early 1980s, several research and development (R&D) programs
were initiated to identify the root causes of problems with braided packing
and to develop improvements that would provide long packing life without
the need for frequent retorquing. This work was performed by EPRI,
Chalk River Nuclear Laboratories, several valve manufacturers and
packing suppliers, and others. Key results of the EPRI sponsored research
are reported in the following documents:
NP-2560
Valve Stem Packing Improvement Study, August 1982 [5]
NP-2455
Valve Stem Packing Improvements, February 1986 [6]
NP-5697
Valve Packing Improvements, May 1988 [7]
This research led to several findings including:
Reduction of the packing height to minimize the effects of

consolidation
Increased use of die-formed flexible graphite packing rings in lieu of

braided rings for the primary seal
The importance of consolidating packing during assembly
The importance of stem condition on friction and wear
The need for packing to remain compliant to accommodate conditions

such as thermally induced taper in the valve stem
The benefit of live loading in accommodating in-service consolidation

without the need for periodic retorquing
These findings are described at greater detail in Section 5.

The result of this work is the configuration of die-formed flexible graphite
packing rings with graphite braid rings above and below the die-formed
rings to prevent extrusion of the die-formed flexible graphite rings at the
gaps between the valve stem and mating parts.
4-4

17
4.1.4 Engineered Die-Formed Flexible Graphite Packing

System (Figure 4-1.d)
Research on valve packing continued throughout the 1980s and 1990s and
led to the development of an engineered valve packing system. This
system consists of:
Die-formed flexible graphite rings
Higher-density graphite or composite anti-extrusion rings
Graphite spacers to reduce the packing height
Graphite bushings to keep the stem centered for cases involving lateral
stem loads
Cushion rings/washers to prevent cracking of spacers at the bottom of

the gland
The use of Belleville washer packs to provide a live load on the gland
Some vendors offer additional features such as the use of wedge-shaped,

die-formed rings to increase the radial sealing stress per unit axial
compressive stress and the addition of thin wafers of PTFE between
packing rings to provide reduced friction with little volume of PTFE
material.
18
4.2 Components in Die-Formed Flexible Graphite

Packing System
19
Figure 4-2 shows a typical modern nuclear plant valve packing system
using die-formed flexible graphite packing rings. The major component
parts are described in Sections 4.2.1 through 4.2.10 of this report. Some of
the parts such as live loading are not used for all applications.
20
21
4-5

Figure 4-2
Typical Component Parts of Engineered Die-Formed Packing
System
4.2.1 Die-Formed Flexible Graphite Packing Rings

Die-formed flexible graphite packing rings form the heart of most modern
nuclear plant valve packing. Laboratory and field experience has
confirmed the superior properties of this material.2 While experience has
demonstrated that sealing takes place over a single ring, most valve
packing sets have two or three flexible graphite rings to provide a backup
and to ensure that there is no leakage past the split in the ring required for
installation.
Several advantages of die-formed expanded graphite packing rings were
identified by the EPRI valve packing improvement study in the 1980s [7]:
2
Experiments using the EPRI VPDU (see Section 8) show how adding a single dieformed flexible graphite packing ring significantly reduces the rate of leakage of
nitrogen gas relative to the leakage for braid ring packing only.
4-6

Low coefficient of friction (less than 0.1)
Self lubricating
No binders, fillers, or resins
Flexible, yet exhibit minimal cold or warm flow characteristics
Corrosion resistance
Very low rate of aging
Excellent resistance to temperature changes
High anisotropy of electrical and thermal conductivity
Capable of 5,432F (3,000C) temperatures in reducing or inert media
Capable of -328F to +932F (-200C to +500C) temperatures in

oxidizing media
No asbestos
Chemically resistant and can operate in fluids with pH of 1 to 14
Available in nuclear grades with low levels of halogens and heavy

metals and leachable chlorides of less than 50 ppm
Available as ribbon, laminated rings, or die-formed rings
Die-formed flexible graphite also has the highest radiation resistance of all
packing materials and has a coefficient of thermal expansion that results in
little differential thermal expansion of the graphite relative to the valve
stem and body materials.
In the 1970s, Union Carbide introduced a Grafoil expanded flexible
graphite to provide superior sealing without the use of asbestos. Flexible
graphite is a high-purity graphite material that has been chemically treated
to form a compound with and between the layers of graphite structure.
This material is heated rapidly to produce an eighty-fold expansion in size
relative to the raw flake graphite material. This expanded material is then
molded or calendered into sheet form with a density of approximately
70 lb/ft3 (1,120 kg/m3) or approximately half of the theoretical 140 lb/ft3
(2,240 kg/m3) of solid graphite [8].
Die-formed rings are manufactured from flexible graphite ribbon that is
wrapped around a mandrel and then compressed in a die to form a single
packing ring. The amount of material used and the compression force
applied determines the density of the manufactured rings. Ring density is
typically in the range of 90100 lb/ft3 (1,4401,600 kg/m3) or 6570% of
the theoretical density of solid graphite.
4-7

Die-formed rings are typically manufactured slightly undersize to ensure

that they will fit without being damaged during installation. Typical
tolerances for die-formed packing rings are +0.005/-0.000 in. (+0.013/0.000 cm) on the inside diameter and +0.000/-0.010 in. (+0.000/-0.025
cm) on the outside diameter. Die-formed rings are typically cut after
forming to create a butt or angled overlap.
22
Die-formed rings typically have a square cross section, but the cross
section can also be a reduced-height rectangular or a wedge shape. The
EPRI valve packing improvement study showed that wedge-shape packing
such as shown in Figure 4-3 can develop a seal under lower axial gland
stresses than square packing. However, subsequent qualification tests and
field experience have demonstrated that square packing can also provide
reliable sealing at acceptable gland preload stresses.
4-8

Figure 4-3
Design and Performance of Wedge-Type Packing [7]
4-9

Laboratory R&D and product qualification tests have demonstrated that

die-formed flexible graphite packing rings form an excellent low-friction
seal against typical valve stem materials. The two main weaknesses of
flexible graphite for this application are that the material must be
contained because it has little inherent resistance to extrusion under high
gland pressures and that it can cause corrosion of the stems.
Flexible graphite for valve packing applications is manufactured with
small amounts of corrosion inhibitor distributed uniformly throughout the
material. The inhibitors are proprietary and their effect on stem materials
must be validated by testing. Section 5.5 of this report describes test
procedures recommended by the Manufacturers Standardization Society
(MSS) to assess the effect of packing materials on stem corrosion.
Additionally, die-formed flexible graphite packing is described in Section
4.3 of the EPRI valve packing improvement study [7].
4.2.2 Anti-Extrusion Rings
Die-formed flexible graphite packing rings have little inherent strength
and tend to extrude under axial loading into gaps between the stem and
body, stem and gland, and gland and body. Three methods are typically
used to prevent this extrusion.
Braided Anti-Extrusion Rings
Rings of braided material can be installed at both ends of the die-formed
flexible graphite rings to prevent extrusion and to help wipe the stem.
These rings need not have any blocking agents because they do not act as
a seal.
Braided seal rings with blocking agents and lubrication can also serve as
anti-extrusion rings. These materials can act to prevent extrusion of the
die-formed flexible graphite rings, provide some additional sealing
capability, and produce less friction.
Alternative types of braid rings are described in Section 4.3 of this report.
Composite Anti-Extrusion Rings
Composite anti-extrusion rings are manufactured from fiber material in a
resin matrix. The dimensions of these rings are such that there is only a
small clearance at the three possible extrusion locations. These rings have
high strength so that they can accommodate axial compressive stresses
without applying high radial loads to the stem. Accordingly, these rings
resist extrusion without increasing friction.
4-10

Composite anti-extrusion rings must be manufactured to close tolerances

so that the gaps between the rings and the stem and stuffing box are tight
enough to prevent extrusion of the die-formed flexible graphite material
yet not so tight that the rings cannot be installed. The need for tighter
tolerances also applies to the stem and stuffing box. If the stem and
stuffing box are not within the specified tolerances for stock composite
anti-extrusion rings, then custom-fit rings must be procured to ensure
proper functioning.
The most detrimental conditions for composite anti-extrusion rings are
applications involving vibration and misalignment. For these applications,
a braided anti-extrusion ring may be more appropriate.
High-Density Expanded Graphite Anti-Extrusion Rings
Anti-extrusion rings can be manufactured using expanded graphite
material compressed to a higher density than the die-formed flexible
graphite sealing rings. This higher-density material is more resistant to
extrusion than normal packing rings, not as sensitive to tolerances as
composite rings, and has a stem friction in between the braided and
composite rings.
Plants typically use both braided and composite anti-extrusion rings. Braid
rings are often selected for routine static applications and composite rings
for critical applications where there is repeated cycling and friction must
be minimized. For cases where composite anti-extrusion rings are used,
consideration should be given to applying live loading. The packing
system must have some compliance to maintain a radial sealing load on
the stem in the presence of small displacements (for example, thermal
taper of the valve stem) and the composite rings have significantly less
compliance than braid rings. The live loading restores compliance to the
system.
4.2.3 Spacers
A main conclusion from early R&D work on valve packing was that
sealing takes place over a relatively short length of packing, dispelling the
belief that a long length of packing was required to ensure a good seal. In
fact, as described in Section 5.2, long lengths of packing increase the
difficulty of achieving consolidation during assembly and increase the
amount of consolidation that occurs in service. Therefore, most modern
packing is based on short packing lengths, with any additional space in the
stuffing box filled by a spacer.
Spacers also act to center the stem in the stuffing box and to accommodate
side loads so that they are not imposed on the packing.
4-11

Spacers are typically manufactured from high-density graphite. This

material is capable of accommodating high gland loads yet not scoring the
stem if contact occurs. The spacers are typically split in half longitudinally
to facilitate assembly, and tapped holes are provided at one end to aid in
removal.
4.2.4 Bushings
In some cases, the valve stem does not run through the centerline of the
gland/stuffing box due to misalignment, stem bowing, or side loads that
occur when the valve is not mounted vertically. This can lead to nonuniform loading of the packing or to the stem contacting the gland and
subsequently being damaged as the valve is stroked. For these cases, a
bushing can be installed at the gland end of the packing set to center the
stem and prevent metal-to-metal contact. Bushings are typically made
from the same high-density graphite material as spacers.
Because bushings can be helpful in many applications, excess length in the
stuffing box should be filled with equal lengths of spacer below the
packing and bushing above the packing.
4.2.5 Lantern Rings
Many valves manufactured before the development of improved packing
were provided with two sets of packing separated by a rigid lantern ring. A
leakage monitoring port was typically used to check for leakage past the
innermost seal.
Given the advancements in packing technology, and the resultant lower
leakage and higher reliability resulting from the use of die-formed flexible
graphite packing, there is less need for the double-packed valves and
lantern rings. In many of these cases, the lantern ring can be removed and
replaced by a longer spacer. However, intermediate monitoring and a
leakoff function is still required for some applications. Modern practice in
these cases is to use graphite lantern rings to avoid the possibility of valve
stem damage.
4.2.6 Packing Washers
Washers made from flexible graphite sheet material are sometimes used to
aid in assembly of the packing. These washers have the same mechanical
properties as the die-formed packing rings but are relatively thin.
4-12

4.2.7 Cushion Rings

As shown in Figure 4-4, graphite spacers can fracture if installed in a
gland that is not flat and square at the bottom. Flexible washers or graphite
braid rings can be used to provide a cushion to prevent fracture of the
spacers. Braid rings provide more cushioning, but their greater height will
result in more friction and potential for service-induced consolidation.
Figure 4-4
Damage to Graphite Spacer Caused by Angled Surface at Bottom of
Stuffing Box [10]
4.2.8 Junk Rings

If the bottom of the gland is machined on an angle, it is generally
necessary to install a metal junk ring or hardened graphite ring
machined to the bottom angle to provide a flat and square surface for the
packing assembly.
Figure 4-4 shows damage that has occurred to a graphite spacer as a result
of high gland preload applied to a valve where the bottom of the stuffing
box was not machined flat and there was no junk ring or cushion ring to
even out the compressive stress.
4.2.9 Gland Bolting and Hardened Steel Washers
23
Gland bolting has been a major source of packing leaks. Specifically, if

the torque applied to the gland nuts does not result in the desired gland
stress on the packing, the packing will not be properly consolidated. As
described in Sections 5.1 and 7.2.2, it is important for the bolting to be in
good condition and to be well lubricated on the threads and the nut-tofollower rubbing surface. In addition, there should be a hardened steel
washer between the nut and gland follower surface to minimize friction
4-13

that prevents the torque from producing the desired gland preload force.
Figure 4-5 shows gland bolting for a typical high-pressure valve with
hardened steel washers to minimize damage and high parasitic friction at
the point where the gland nut turns against the follower surface.
Figure 4-5
Typical High-Pressure Valve Gland Bolting Without Live Load [10]
4.2.10 Live Loading

The final component of a modern packing system is live loading to
compensate for in-service consolidation and to provide compliance for
cases involving composite anti-extrusion rings. This loading is most often
provided by a stack of Belleville (spring) washers installed between the
follower and nut as shown in Figure 4-2. Spring packs must be properly
engineered to provide the required gland force and displacement
capability. Live loading is described in greater detail in Section 7.4 of this
report.
4-14

4.3
Components in Braid Ring Packing System
For some applications, utilities use braid rings in lieu of die-formed

flexible graphite rings and anti-extrusion rings. Cost and convenience are
the primary reasons for selecting braid rings. However, this configuration
is not generally as good as one using die-formed flexible graphite because
the braid rings are more susceptible to consolidation, hardening, and loss
of blocking material over time.
A valve packed with braid rings can have all of the other features of a
valve packed with die-formed flexible graphite rings such as spacers,
bushings, packing washers, junk rings, and live loading.
Braided packing consists of a braided material and a blocking agent to seal
leaks between adjacent fibers. Braided packing can also include corrosion
inhibitors and lubricity additives such as PTFE, graphite powder, or oil.
The main product forms are described in Sections 4.3.1 through 4.3.5.
4.3.1 Braided Asbestos
Braided asbestos packing is no longer installed in valves due to the health
hazard posed by the asbestos fibers and the generally poor performance
resulting from loss of the blocking agents and resultant hardening over
time.
4.3.2 Braided PTFE
Braided PTFE is used for low-temperature (<200F [93C]) water
applications where halogen-containing materials can be accepted. This
material is typically supplied as braided virgin PTFE or braided expanded
PTFE. It is not generally necessary to include blocking agents or lubricity
additives because PTFE flows to fill internal voids and has naturally low
friction characteristics. PTFE is not suited to higher temperature service
because the material can break down (decompose) and the PTFE has a
much higher coefficient of thermal expansion than metal valve bodies.
The higher coefficient of thermal expansion results in the expansion of the
packing with increasing temperature and resultant extrusion and
consolidation. PTFE also has relatively poor radiation resistance that can
limit its use in higher radiation fields. The EPRI study NP-4172SP,
Radiation Data for Design and Qualification of Nuclear Plant Equipment
[9], indicates that PTFE should be limited to approximately 104105 rads.
For a five-year packing life, this would limit the use of this material to
locations with less than approximately 2002000 mr/hr (2 x 10-32 x 10-2
S/hr).
4-15

4.3.3 Braided Graphite Fiber Yarn

Graphite fiber yarn can be woven into packing rings. The packing is
typically provided with blocking agents and lubricants to improve sealing
and reduce friction. PTFE is particularly useful as a blocking agent
because it reduces friction, but might not be acceptable for all applications
for the reasons noted in Section 4.3.2. Graphite fibers are much larger in
diameter than asbestos fibers and are susceptible to fracturing at the
extrusion gap for gland pressures higher than 46 ksi (2842 MPa).
However, for most nuclear plant applications, it should not be necessary to
use gland pressures greater than 4 ksi (28 MPa); and braided graphite has
been used successfully in these applications.
4.3.4 Braided Carbon Fiber Yarn
Carbon fibers have greater strength than graphite fibers, are smaller in
diameter, and are less susceptible to fracture at high gland stresses. As in
the case of graphite fiber yarns, blocking agents and lubricants are added
to improve sealability and reduce friction.
4.3.5 Braided Flexible Graphite Tape
Flexible graphite tape can be formed into large strands and braided into
square packing. The flexible graphite tape strands can be wrapped with
small-diameter, corrosion-resistant wire to increase extrusion resistance.
Blocking agents and lubricants can also be added to improve sealability
and reduce friction. While the fine wire wrap improves resistance to
extrusion, it has the potential to score the stem, especially under highcycle applications.
In summary, several types of braided packing have been used successfully
in nuclear plant applications. The main disadvantages relative to dieformed flexible graphite packing are that braided-type products have
greater consolidation in service and are susceptible to loss or degradation
of the blocking materials over time. For these reasons, braided-type
packing typically requires more frequent retorquing and more frequent
replacement to achieve the same level of leak tightness as die-formed
flexible graphite packing.
24
25
26
4.4
Commercial Products
Valve packing is provided by valve manufacturers and independent

packing suppliers. Table 4-1 provides a summary of products offered by
three leading packing suppliers. Similar products are offered by other
suppliers. Because products are continually being improved, users should
contact suppliers for the most current information.
4-16

Table 4-1
Valve Packing Products Commercial Products Survey
Products Offered by Major Suppliers
Product Type
Alternative
Products
Positive Features
Negative Features
Die-Formed
Graphite Packing
Rings
Square or
Rectangular Rings
Excellent sealing
Low friction
Low consolidation
Cost and increased inventory

Tolerance sensitivity
Increased installation effort
Note: All die-formed

rings are susceptible
to extrusion
Wedge-Shaped
Rings
Excellent sealing (low gland stress)

Lowest friction (low gland stress)
Low consolidation

Anti-Extrusion Rings
Graphite Yarn Ring
Low cost
Low halogen
Not tolerance sensitive
Consolidation
Increased friction
Gland stress limited to 46 ksi
High-Density DieFormed Graphite
Low friction
Low consolidation

Composite Ring
Graphite/Resin
Lowest friction
Low consolidation
High cost and increased

inventory
Spacers and
Bushings
Solid Graphite Rings

Split for Assembly
Contribute to better seal

Contribute to lower friction
Bushings take side loads
Increased cost and inventory

Bushings tolerance sensitive
Washers
Graphite Sheet
Rings
Low cost
Aids in assembly
Cushions bottom of spacer
Extra cost and inventory

Argo
Chesterton
Garlock
6300 J
5200
5300
GRAPH-LOCK
Rings
5800
9000-EVSP
includes various
end ring types
One
One-CI
G-700
5600
GRAPH-LOCK
Rings
524
6000
5005 std-density
5010 high-density
6200 N
N/A
5100
4525
N/A
4-17

Table 4-1 (cont.)
Valve Packing Products Commercial Products Survey
Product Type
Alternative
Products
Positive Features
Negative Features
Argo
Chesterton
Garlock
N/A
N/A
Braided Packing
Rings
Asbestos Yarn
Graphite/Mica Filler
Not applicable since no longer

being installed
Health hazard
Hardening in service
N/A
Note: All braid-type

packing is
susceptible to
consolidation
Graphite Fiber Yarn

Graphite BA/Lube
Low cost
Low halogen
Increased friction w/o PTFE

7300
N/A
Graphite Fiber Yarn

PTFE BA/Lube
Low cost
Low friction
Small amounts of PTFE

525
G-200
Carbon Fiber Yarn

Graphite BA/Lube
Low cost
Low halogen
526
N/A
Carbon Fiber Yarn

PTFE BA/Lube
Low cost
Low friction
5000
#98
Graphite Tape
High Temp BA
Low cost
Low halogen

Needs braid end ring for >1200
psi
7000
1400
GRAPH-LOCK
Tape
Graphite Tape
Wire Reinforced
Low cost
Low halogen

Potential leakage
Wire reinforcement
7300-I
1601
1398
1399
Graphite Tape
Wire Reinforced
PTFE BA/Lube
Low cost
Low friction

Wire reinforcement
7301-I
1600
1303-FEP
4-18

4.5
Summary
Valve packing has evolved over the years from braided asbestos
packing rings, to non-asbestos braid rings, to die-formed flexible
graphite rings with braid ring backup, to fully engineered die-formed
flexible graphite packing systems.
All of the available systems are currently in use for replacements

except for asbestos braid rings.
The best approach for most nuclear plant valves is to use die-formed
flexible graphite packing rings with appropriate (braided or composite)
anti-extrusion rings.
It is not necessary to use a fully engineered die-formed flexible

graphite packing system with composite anti-extrusion rings and live
loading for all applications. In many cases, simple die-formed flexible
graphite packing with braid type anti-extrusion rings will provide
acceptable service.
A packing system can contain many parts including braid rings, dieformed flexible graphite rings, anti-extrusion rings, spacers, bushings,
lantern rings, washers, junk rings and live loading. Selection of the
best assembly of parts for given applications is described in Section 6
of this report.
A summary table of commercial products from three suppliers is

included to illustrate the range of products offered. Users are
encouraged to solicit up-to-date information from these and other
suppliers regarding available products.
4-19
CAUSES OF VALVE PACKING LEAKS
28
This section describes the main causes of leaks from valve packing and the
measures that can be taken to mitigate these causes.
A common misconception is that the majority of packing leaks are caused
by the material simply wearing out. This often leads to the conclusion
that valve packing leakage is inevitable. However, experience with wellexecuted valve packing programs has demonstrated that properly packed
valves do not leak and do not require frequent retorquing or repacking. It
is, therefore, important for engineers and maintenance technicians to
search for and to resolve the actual root causes of leaks rather than just to
repack leaking valves using previously used methods.
29
5.1
Low Gland Stress
The gland stress must be high enough to create and maintain the seal
under operating conditions. The required gland stress is described in
Section 7. For most nuclear plant applications using die-formed flexible
graphite packing rings, the gland preload stress should be 3,0004,000 psi
(2128 MPa) to ensure proper initial consolidation and to provide margin
for the inevitable loss in preload over time due to service-induced
consolidation and wear.
Gland preload is typically applied by torquing gland nuts. However, the
amount of load on the gland produced by the torque depends on factors
including the applied torque, friction between the nut and gland stud
threads, friction between the nut and follower, surface condition of the
threads and the nut/follower interface, and the type of lubricant used. In
this regard, gland bolting behaves essentially the same as flange bolting.
Work in EPRI TR-111472, Assembling Bolted Connections Using SpiralWound Gaskets [11], another document in the Sealing Technology & Plant
Leakage Reduction Series, shows that the actual bolt load can be as little
as one-third of the desired load for a given torque depending on these
factors. The actual load is rarely higher than the desired load.
The keys to achieving the desired gland preload stress are typically to
have:
A suitably high target stress

5-1

Causes of Valve Packing Leaks
Clean studs/nuts
Smooth contact surfaces between the nut and follower
Good lubrication at the threads and between the nut and follower
Proper consolidation as described in Sections 5.2 and 7.2.3
30
5.2
Packing Consolidation
31
By design, valve packing is compliant to allow it to fit to imperfections in

the stem and stuffing box during assembly and to follow small
displacements during valve stroking. Braid ring-type packing must
typically be compressed 2550% by volume during assembly to close up
voids. Figure 5-1 shows that typical 90 lb/ft3 (1,440 kg/m3) initial density
die-formed graphite packing must be compressed 1520% by volume
during assembly.
Figure 5-1
Consolidation of Die-Formed Flexible Graphite Packing [7]
If the packing were frictionless, a gland stress of 4,000 psi (28 MPa)
would be sufficient to compress most packing materials to the desired
density. However, as shown in Figure 5-2, friction between the packing,
stem, and stuffing box can result in parts of the packing not being properly
5-2

32
33
compressed. As shown in this figure, the top of the packing that is loaded
by the gland is subjected to the desired compressive stress while the
bottom of the packing has a lower compressive stress due to friction at the
stem and stuffing box wall. During operation, thermal cycling and valve
stroking will result in the decrease of compressive stress at the initially
higher stress locations, and the increase of compressive stress at the
initially lower stress locations. With time, the packing will shake down
to an equilibrium stress that is less than the initial target compressive
stress. It is said that the packing has consolidated in service and the
resultant lower gland stresses may result in leakage.
Figure 5-2
Packing Consolidation [7]
Service-induced packing consolidation is obviously a more significant

factor in applications involving:
Deep stuffing boxes
Braided-type packing that requires greater initial compression to fill up

voids and has the potential for loss of blocking material over time
High-friction packing
Rough stem and stuffing boxes surfaces that contribute to high friction
The main solutions to service-induced consolidation are:
Use packing materials that require less consolidation (die-formed

flexible graphite sealing rings with composite anti-extrusion rings).
Use lower-friction coefficient packing materials (PTFE-filled, antiextrusion braid rings in lieu of unfilled graphite anti-extrusion braid
rings where practical).
Reduce the packing height by using bushings or spacers, minimizing

the number of seal and anti-extrusion rings, and using rectangular
(reduced-height) die-formed flexible graphite packing rings.
5-3

34
Ensure that the valve stem and stuffing box finish are smooth so that
unnecessary friction is not created.
Ensure that the bolting materials are in good condition and lubricated,
and, preferably, include a hardened steel washer between the nut and
follower so that the specified torque results in the desired gland
preload force.
Repeatedly stroke the valve stem and retorque the gland nuts until
there is no further gland nut rotation for the specified final torque. At
this point, the packing should be uniformly compressed and there
should be little relaxation of gland load during service. Figure 5-3
illustrates the beneficial effect of initial consolidation. This can require
many cycles of stroking and torquing the gland nuts.
Figure 5-3
Effect of Consolidation on Gland Load [7]
Finally, for problem valves, valves that are in cyclic service, or critical
valves that cannot be retorqued during plant operation, live loading
(typically Belleville washers) can be used to maintain the desired
compressive load on the packing and thereby compensate for serviceinduced consolidation or wear.
5-4

35
36
5.3
Dimensions and Clearances
Because packing is designed to be compliant and therefore able to

accommodate imperfections in valve parts and small displacements during
operation, excessive clearances can cause problems.
Excessive gaps between the stem and gland, gland and stuffing box, and
between the stem and stuffing box can allow the packing material to
extrude into the gaps between the mating parts, especially under cyclic
motions. Extrusion can result in loss of gland preload stress, accelerated
packing wear, or in wedging of the stem with resultant increased friction.
37
38
39
The MSS Standard Practices (SP) 120, Flexible Graphite Packing System
for Rising Stem Steel Valves (Design Requirements) [12], provides
suggested tolerances for each of the main parts that affect performance of
valve packing. Figures 5-4 through 5-6 show suggested clearances and
tolerances for the stuffing box, stem, and gland. If problems are
encountered, the clearances and tolerances should be reviewed. Solutions
include replacing out-of-spec parts or using an alternative packing system
that better accommodates the as-found conditions. Packing suppliers
should be consulted for the best solution for difficult or important cases.
Figure 5-4
Running Tolerances and Clearances (MSS SP-120) [12]
5-5

Figure 5-5
Stuffing Box Tolerances (MSS SP-120) [12]
Figure 5-6
Stem Tolerances (MSS SP-120) [12]
5.4
40
Stem and Stuffing Box Surface Finish
The stem surface must be smooth to create a good seal, to allow for proper
initial packing consolidation, and to minimize packing wear and friction.
Guidance regarding stem condition includes:
MSS SP-120 specifies that the stem surface should have a finish of 32
inch (0.81 meter) root mean square (RMS) or better and should be
free of scratches, pits, or voids deeper than 0.002 in. (0.051 mm)
Union Carbide states that a surface finish of 32 inch (0.81 meter)

RMS is acceptable for hand-operated valves but that a surface finish of
16 inch (0.41 meter) RMS is better for control valves [8]
5-6

Fisher Controls Monograph 38 reports that their control valve stems

are polished to a surface finish of 4 inch (0.10 meter) RMS or better
[13]
In summary, the stem surface finish is important, and smoother finishes

are typically desirable for control valves that involve large numbers of
operating stroke cycles. Surface finishes can be checked in the field using
a comparator.
41
42
The stuffing box surface finish is also important in achieving proper

packing consolidation. While not specified by MSS SP-120, a surface
finish of 32 inch (0.81 meter) RMS should be achievable in the stuffing
box. MSS SP-120 does specify that the stuffing box inside surface should
be free of scratches, pits, or voids deeper than 0.006 in. (0.152 mm).
5.5
Stem and Stuffing Box Corrosion
Corrosion of the stem and stuffing box surfaces is detrimental to packing

consolidation and service-induced wear. There is significant potential for
corrosion using graphitic packing materials that are cathodic with respect
to the metal parts and are electrically conductive.
43
MSS SP-120 specifies that flexible graphite packing shall contain a

dispersed passive corrosion inhibitor, a dispersed embedded active
corrosion inhibitor, or a suitable combination of corrosion inhibitors to
minimize the potential for stem pitting. MSS SP-121, Qualification
Testing Methods for Stem Packing for Rising Stem Steel Valves [14],
specifies that corrosion tests shall be performed on packing systems.
Figure 5-7 shows the specified corrosion test specimens. Test conditions
and acceptance criteria are specified in MSS SP-121.
5-7

Figure 5-7
Stem Corrosion Test Fixture (MSS SP-121) [14]
Corrosion has been a significant concern with valves and valve parts
stored in warehouses where there is moisture, or in locations where
packing is wet due to water trapped during valve hydrostatic testing. Some
utilities have avoided these conditions by removing the packing during
storage. Installing new packing when the valve is placed in service will
ensure that the new valve is packed to the latest plant standards.
44
5.6
Stem Misalignment
Several adverse conditions can occur if the valve stem is misaligned.

These include:
Contact between the stem and gland can cause friction, wear, and
degradation of the stem surface finish
Lateral loads on the packing can potentially cause corrosion, and under
worst case conditions, open up a gap between the stem and packing
Wedging of the gland on the stem so that the gland force is not applied
to the packing (this is often a problem for valves with short glands)
Typical effects of stem misalignment are illustrated in Figure 5-8. Stem

misalignment can result from several causes including a bent stem, a
misaligned stem, side loads on the stem (often occurs with valves mounted
off-vertically), and the stuffing box walls not being perpendicular to the
bonnet flange surface.
5-8

Figure 5-8
Typical Effects of Stem Misalignment [10]
45
In most cases, the solution to misalignment is to ensure that the parts (for
example, stuffing box, stem, and gland) meet previously noted
dimensional tolerances. It can be desirable to include graphite bushings at
the top and bottom of the packing set as illustrated in Figure 5-9. The
bushings act to keep the stem centered in the packing and to take side
loads.
5-9

Figure 5-9
Use of Bushings to Mitigate Stem Misalignment
46
47
5.7
Stem Thermal Taper
Thermal expansion of valve stems can lead to packing leaks as illustrated

in Figure 5-10. Specifically, the portion of the stem deep in the valve can
operate at a higher temperature than the portion of the stem in contact with
the packing. As the valve stem is retracted, the hotter portion of the stem,
which will be slightly larger in diameter due to the higher temperature, is
pulled up into the packing region where it expands the packing outward.
This outward displacement of the packing produces further packing
consolidation. When the valve stem cools, or the stem is stroked back into
the valve, the packing might not follow the resultant reduction in stem
diameter. This can produce a leak.
5-10

Figure 5-10
Effect of Stem Thermal Taper on Packing Consolidation
There are several possible solutions to this problem. These include:
48
Use packing with a greater amount of compliance to accommodate

small amounts of radial expansion. For example, use braided antiextrusion rings rather than composite anti-extrusion rings.
Provide live loading (Belleville springs) that acts to keep the packing
loaded at all times.
5.8
Product Misapplication
Many packing leaks result from misapplication of packing products.

Sections 4 and 6 of this report provide information regarding the main
types of products that are available and the best applications for these
products. Several examples of problems that can result from
misapplication are:
Virgin PTFE packing has a coefficient of thermal expansion more than

six times that of typical stainless steel valve parts. As a result, the
packing expands more than the valve body as the valve heats up
causing high loads in the packing and possible extrusion through gaps
between the gland and stem, gland and stuffing box, and between the
stem and stuffing box. Extrusion can lead to loss of compressive load
on the packing after cooldown and the loss of sealing function. This
suggests that virgin PTFE should be limited to lower temperature
applications.
5-11

Virgin PTFE has very little creep resistance at temperatures over

100F (37.78C) so that it is susceptible to extrusion between the stem
and gland, gland and stuffing box, and stem and stuffing box.
Microcellular or expanded microcellular PTFE has much better creep
resistance than virgin PTFE.
PTFE begins to decompose at temperatures of approximately 600F

(315.56C) as shown in Figure 5-11 [13]. Given the significant
coefficient of thermal expansion and the potential for material
degradation, pure PTFE packing should generally be limited to 200
300F (93.33148.89C). However, higher allowable temperatures
have been reported for packing involving PTFE as a blocking material
in graphite braid packing. In these cases, the graphite braid resists the
higher temperatures and the PTFE acts solely to block leakage and
ensure low friction.
PTFE materials are limited to an integrated radiation exposure of 104

105 rads [9]. This factor eliminates PTFE packing from consideration
at high radiation locations.
Graphite fibers tend to fracture at gland stresses of 4,0006,000 psi

(2841 MPa). However, because most nuclear plant packing can be
limited to 4,000 psi (28 MPa), this should not pose a practical concern.
It is reported that carbon fibers can accommodate higher gland stresses
without fracturing.
Graphite bushings or spacers used to reduce packing height and to

resist lateral stem loads are hard materials that can crack if not
properly supported (see Figure 4-4). This is a special concern if the
bottom surface of the stuffing box is not flat. Solutions for problems at
this location include installation of: 1) a braid ring to cushion the
spacer, 2) die-formed flexible graphite washers between the spacer and
bottom of the stuffing box to cushion the bottom of the spacer, or 3)
machined metal rings in the bottom of the stuffing box to ensure a flat
perpendicular surface.
49
50
5-12

Figure 5-11
Decomposition Rate of PTFE at Elevated Temperature [13]
5.9
Aging
Packing can age under operating conditions and typically results in the
loss of blocking agents or lubricants that reduce the sealability and
increase friction. Aging can also result in hardening of packing so that it
no longer follows operationally induced displacements. The main issue is
whether the life achieved is acceptable or if changes should be made to
use materials that have a potentially improved life.
Pure graphite materials, such as die-formed flexible graphite and braid
rings without fillers, are not susceptible to aging mechanisms that affect
many other materials. Therefore, pure graphite products should be selected
for applications where long life is desired.
51
5.10 Functional Failure Due to Excessive Friction

Many applications require low or repeatable friction for proper
functioning. High friction can result in difficulty in opening or closing
valves, and this can represent a functional failure. This is especially a
concern with air and motor operated valves (AOVs and MOVs) that
typically require a low and reproducible friction.
5-13

Several methods can be used to reduce stem friction. These are:
Use shorter packing heights to produce less friction than longer

packing heights. This is especially appropriate if the packing has been
fully consolidated and has a uniform radial force per unit length. The
longer the length, the higher is the friction.
Use rectangular die-formed flexible graphite packing rings to

minimize the length of the seal rings.
Use composite-type anti-extrusion rings to minimize friction at this

location.
Use low-friction packing materials. Packing materials have different

coefficients of friction against the stem. Given equal sealability, it is
generally preferable to use a lower-friction packing material.
When braid rings are used for sealing or anti-extrusion rings, include
small amounts of PTFE in the packing to reduce friction where
technically acceptable. Small amounts of PTFE can be dispersed in the
packing material, or thin PTFE washers can be provided between
packing rings. In both cases, the PTFE will tend to flow and provide
lubricity at the stem to packing interface.
Ensure that the valve stem is smooth and free of corrosion products. A
rough and corroded surface will increase friction and accelerate
packing wear.
Reduce the gland preload in some cases. However, lower gland

stresses may not result in proper consolidation for long-term reliable
service without retorquing. Accordingly, gland preload stresses should
be reduced with engineering supervision, and may result in the need
for applying live load or specifying more frequent retorquing.
5.11 Summary
There are many causes of valve packing leaks. Key factors include:
Low gland stress
Packing consolidation
Poor operating clearances: too tight and too loose
Rough stem and stuffing box surface finish
Stem and stuffing box corrosion
Stem misalignment
Stem thermal taper
Product misapplication
Aging
5-14

Valve packing can also contribute to functional failures due to high

friction.
These causes of packing failure should be reviewed with the selected

packing supplier to ensure that the best materials are used.
This list of causes should be reviewed when performing root cause

analysis of premature packing leaks.
5-15
SELECTING PACKING CONFIGURATIONS

AND PRODUCTS
This section describes the main factors to be considered in selecting

packing configurations and products for general application. This
information is best used as a guide to assist utilities in selecting products
and suppliers. It should be supplemented as appropriate by information
from other sources such as valve and packing suppliers, other utilities, and
independent test laboratories.
To put the subject of ideal packing configurations into perspective, while a
typical plant will have a few packing configurations that are widely used,
it will also have a large number of unique packing configurations for
special purpose applications. The information in this section is directed
toward the small number of standard configurations used for large
numbers of valves.
53
6.1
Overview of Packing Options
The ideal packing would have high leak-tight integrity, low friction, ease
of installation, no need for tight tolerances, minimal inventory
requirements, and low cost. Work in the EPRI sealing technology program
suggests that this objective can be achieved using a relatively simple
building block approach.
The foundation is a packing configuration consisting of two to three

die-formed flexible graphite packing rings with plain braided graphite
anti-extrusion rings at either end. The remainder of the stuffing box
should be filled by a graphite spacer and possibly a graphite bushing.
A flexible graphite washer or braid ring should be installed beneath the
spacer to provide cushioning. Hardened steel washers should be used
between the gland nuts and the top of the gland follower to minimize
friction loss at this important location. For cases requiring low friction,
the number of die-formed flexible graphite rings can be reduced and
square rings can be replaced by reduced-height rectangular rings.
For cases where even lower friction is required, the plain braided
graphite end rings can be replaced with lubricated graphite braid rings
or with composite rings.
6-1

Selecting Packing Configurations and Products
For lower temperature and pressure applications, where there is access

for periodic retorquing, all lubricated braid ring packing can be
considered without the need for die-formed flexible graphite rings.
In summary, the suggested approach is to start with a standard high quality

but simple product, use lower friction end rings where required, and limit
the use of all braid ring packing to the least critical applications where
there is access for periodic retorquing.
54
6.2
Packing Coding System
Utilities should have a coding system to designate the elements of the

packing for a specific application. Utilities can use packing coding
systems offered by suppliers, or they can create their own system.
The following designations are used in this report:
X =
Z =
0
C
H
S
B
W
=
=
=
=
=
=
braided graphite ring

lubricated graphite rings (PTFE, graphite/oil, wire-wrapped
graphite tape)
die-formed flexible graphite ring
composite anti-extrusion ring
high-density anti-extrusion ring
graphite spacer
graphite bushing
flexible graphite washer
A typical five-ring set with three die-formed graphite rings and braided
graphite end rings would be designated:
top
bottom
X000X
6.3
Suggested Packing Configurations
While many packing configurations are possible, utilities should consider

standardizing on three basic configurations for most applications. These
are described in Sections 6.3.1 to 6.3.3.
55
6.3.1 Basic Die-Formed Flexible Graphite Packing

(BX000XSW)
This configuration should represent the heart of most plants valve
packing system. Two or three die-formed flexible graphite packing rings
provide excellent sealing, low consolidation, and modest friction at
modest cost. Braided graphite anti-extrusion end rings prevent extrusion of
the die-formed flexible graphite rings with modest friction and with the
potential for consolidation due to loss of blocking material.
6-2

A graphite spacer below and a graphite bushing above the packing rings
minimize the amount of material to be consolidated, provide for alignment
of the stem in the stuffing box, take side loads, and minimize the potential
for wear of the stem against metal parts. Finally, a flexible graphite washer
below the graphite spacer minimizes the potential for cracking of the
bottom edge of the spacer. Hardened steel washers should be used
between the gland nuts and follower in all cases.
For applications where friction must be minimized within the standard
package, half-height rectangular rings can be used, or the number of dieformed flexible graphite rings can be reduced to two or, in some cases,
even one.
56
6.3.2 Low-Friction Packing

Where friction must be further reduced, two main approaches are
suggested. The first is to use lower-friction, braided-type anti-extrusion
rings in place of the plain graphite braid rings. The second is to use
composite or high-density graphite anti-extrusion rings that do not expand
as much in the radial directions and therefore do not apply as high radial
loads that generate friction forces. In either option, the number of dieformed flexible graphite seal rings can be reduced and they can be reduced
height rectangular rather than square form.
Die-Formed Flexible Graphite With Low-Friction Braid Anti-Extrusion
Rings (BZ00ZSW)
The ideal blocking material for low-friction braid rings for static and
dynamic applications is PTFE when permitted by plant chemistry
specifications. These types of rings have been used in secondary side
applications and some primary system applications in both boiling water
reactor (BWR) and PWR plants. Where PTFE cannot be used, graphitelubricated graphite braid rings or wire-wrapped braided flexible graphite
tape can be used.
The PTFE and graphite lubricants used as blocking materials can be lost
with time, resulting in consolidation and the need for more frequent
retorquing relative to unlubricated graphite braid rings. The wire wrap
used for flexible graphite tape anti-extrusion rings can cause damage to
valve stems in cyclic duty applications.
Die-Formed Flexible Graphite With Composite Anti-Extrusion Rings
(BC00CSW)
For the most demanding low-friction applications, it can be desirable to
use composite anti-extrusion rings. These rings should provide the lowest
6-3

friction. However, the stiff composite anti-extrusion rings have little

compliance, and it might be necessary to install live load to maintain the
intended preload and to provide for small deflections that occur in service.
57
6.3.3 All Braid Non-Asbestos Packing (BZZZZSW)

All braided non-asbestos packing should generally be limited to the least
important lower temperature applications where long packing life is not a
requirement and where there is access for retorquing. The main advantage
of this packing system is its low cost and ease of assembly by lesser
skilled craft. All braid ring packing sets should not generally be used
where high leak-tight integrity is required.
6.4
Other Packing Configurations
These four configurations should cover most valves at a typical plant.

However, there are many exceptions, such as valves with very short
stuffing boxes where the number of rings must be held to a minimum. For
the case of shallow stuffing boxes, the same approach as described in
Section 6.3 can be used, but with fewer rings, that is, Z00Z.
Vendors should be contacted for the many special purpose applications.
58
6.5
Inventory Optimization
If complete packing sets are stocked for each different configuration used
in the plant, then a large number of different sets must be procured and
stored.
An alternative approach is to limit the complete sets to fully-engineered
packages with composite anti-extrusion rings and possibly live loading for
the most critical or problem valves. For the balance of the valves, dieformed flexible graphite rings, plain braided graphite end rings, lowfriction braid graphite end rings, graphite bushings/spacers, flexible
graphite washers, and Belleville springs can be procured and stocked in
standard sizes and the packages assembled from the parts as needed. The
assembled parts can be packaged in a box or tube and issued to the craft
performing the work. This approach would protect the parts prior to
assembly and reduce the probability that incorrect parts will be used.
Assistance in inventory optimization can be obtained from packing
suppliers.
6-4

59
6.6
Evaluating Packing Suppliers and Products
6.6.1 Vendor Support

Several firms offer valve packing products. Utilities should select a
supplier based on experience and the quality of the product and services
offered. Factors in this evaluation should include:
Products offered
Experience with these products
Qualification test programs
Home office engineering support
Field engineering support
Assistance in establishing inventory optimization programs
Training programs
Delivery time for infrequently used packing sets
The experience of other utilities should be solicited as part of this

evaluation.
6.6.2 Product Qualification Testing
Packing products should be selected based on field experience and/or
qualification tests. Qualification test results should be available from
vendors and independent test laboratories. MSS SP-121 [14] specifies
methods for qualification testing including test fixtures and
instrumentation, test procedures, acceptance criteria for static and dynamic
tests, and corrosion tests of packing and stem materials.
6.7
Summary
Valve packing should be selected to provide leak-tight integrity, low

friction, ease of installation, and minimal inventory requirements at
low cost.
Valve packing objectives are often achieved using a building block

approach:
Use die-formed flexible graphite packing rings with graphite braid

anti-extrusion rings for most applications. If low friction is
required, use reduced-height flexible graphite rings, and possibly
reduce the number of die-formed rings.
6-5

When friction must be further reduced, replace the plain graphite

braid anti-extrusion rings with lubricated graphite or composite
rings. Composite rings may necessitate use of live loading due to
its significantly lower compliance.
Generally limit all lubricated braid ring packing to low temperature

and pressure applications where there is access for periodic
retorquing.
Plants should develop a packing coding system to facilitate a common

understanding of the type of packing required for each application.
Inventory optimization can include procuring valve packing

component parts such as braid rings, die-formed flexible graphite
rings, graphite bushings, graphite spacers, flexible graphite washers,
and Belleville springs, in bulk and assembling packages as needed.
Vendor pre-packaged sets can be limited to the most critical or
problem applications.
Utilities should select a packing supplier based on experience and the

quality of products offered. Factors in the evaluation should include
products offered, experience with the products, qualification test
programs, home office engineering support, field engineering support,
assistance in establishing inventory optimization programs, training
programs, and delivery time for infrequently used packing sets.
Packing should be qualified using tests specified in MSS SP-121 [14].
6-6
GLAND PRELOAD
This section describes the required gland preload, achieving preload by

torquing, stem friction, live loading, gland design, and stem friction force
monitoring in AOVs and MOVs.
61
7.1
Gland Preload Stress and Required Sealing Force
Work in EPRI NP-5697, Valve Packing Improvements [7], suggests that

most packing should be preloaded to produce an axial stress of
approximately 1.75 times the system pressure on the packing or
approximately 2,000 psi (14 MPa) for BWR plant primary systems and
4,000 psi (28 MPa) for PWR plant primary systems. However, subsequent
field experience has shown that most packing should be preloaded to
approximately 4,000 psi (28 MPa) to ensure that the material is properly
consolidated and to provide a margin for loss of gland preload due to
service-induced consolidation or wear. Proper consolidation cannot
generally be ensured at lower preloads.
While 4,000 psi (28 MPa) is a good general packing preload stress for
nuclear plant applications, users are encouraged to review the packing
preload with their suppliers because higher or lower preload stresses may
be appropriate for certain packing applications.
62
The required gland force is the gland preload stress times the gland cross
sectional area:
Fg =
Pg Do Di
2
where
Fg
Pg
Do
Di
=
=
=
=
the required gland force

the required gland pressure
the gland outside diameter (stuffing box diameter)
the gland inside diameter (stem diameter)
7-1

Gland Preload
This equation can be simplified to:
Fg = 0.7854 Pg Do 2 Di 2
7.2
Achieving Preload by Torquing
In most cases, the gland loads are applied by torquing the nuts on the
gland studs to the level necessary to achieve the desired preload force.
There are three main factors involved in achieving preload by torquing: 1)
determining the appropriate torque, 2) ensuring that the material
conditions will result in achieving the desired preload when the specified
torque is applied, and 3) providing for packing consolidation.
7.2.1 Determining Appropriate Torque
63
The bolt load vs. torque relationship is addressed in EPRI TR-111472,

Assembling Bolted Connections Using Spiral-Wound Gaskets [11].
Section 5 of this report indicates that the torque required to achieve a
desired preload force can be determined using the nut factor equation:
Tp =
KDFg
12 N
where
Tp
K
D
Fg
N
=
=
=
=
=
applied preload torque (ft-lb)

nut factor
nominal stud diameter (in.)
the required gland force
number of gland studs acting on gland follower
Combining these two equations gives the following expression for the
required torque as a function of the desired gland stress:
Tp =
KD
0.7854 Pg Do 2 Di 2
12 N
)]
For the case of studs and nuts in good condition, and well lubricated with
a high-pressure nickel- or graphite-based thread lubricant on the threads
and between the nut and follower, the nut factor (K) can be taken as 0.16.3
3
Experiments conducted using the EPRI Bolting Performance Demonstration Unit

have confirmed the torque vs. load relationships given by Crane. These data are
consistent with a nominal nut factor of 0.16.
7-2

Gland Preload
64
In addition, most applications involve two gland studs. Therefore, the

required torque can be simplified further to:
T p = 0.00524 Pg Do 2 Di 2 D
7.2.2 Ensuring That Applied Torque Results in the Desired

Preload
In addition to specifying the proper preload torque, the procedure should
include steps to ensure that the applied torque develops the desired preload
force in the stud. The following factors should be addressed:
Thread Condition
Threads must be in good condition and free of yielding, burrs, rust, or
paint in order to develop the proper preload force for a given torque.
Friction produced by damage, corrosion, or paint reduces the amount of
the applied torque that is transferred while tightening the stud. Minor
corrosion should be removed by wire brushes and damaged studs/nuts
should be replaced. If there is any question regarding the condition of the
studs, it is useful to test by running the nuts down over the threaded stud
length. Binding of the nut along the path can suggest that the stud has been
stretched or otherwise damaged.
65
Flange and Nut Surface Condition

Most of the applied torque is transferred into overcoming sliding friction
between the nut and follower. Poor conditions at this surface increase
friction and reduce the amount of the applied torque that actually is
transferred into tightening the stud. Accordingly, this surface must be flat,
smooth, and clean. Figure 7-1 shows a typical follower surface that has
been damaged by the nut galling during torquing. Galling at this location
can be prevented with hardened steel washers between the nut and
follower surface as shown in Figures 4-1.c and 4-5.
7-3

Gland Preload
Figure 7-1
Galling on Follower Caused by Lack of Hardened Steel Washers
[10]
Hardened Steel Washers

Hardened steel washers should be used between the gland nut and
follower to produce an ideal low-friction surface and to prevent damage to
the follower when the nuts are torqued. Frequently, valve suppliers do not
supply washers between the gland nuts and follower. In some cases,
supplied washers have been soft steel rather than hardened steel. As shown
in Figure 7-2, soft washers are easily damaged when the gland nuts are
torqued, resulting in little, if any, benefit.
Figure 7-2
Galling of Soft Steel Washers Provided by Valve Supplier [10]
7-4

Gland Preload
Lubrication
Lubrication should be applied to the stud threads and also to the surface
between the bottom of the nut and the follower or hardened steel washer.
Further details regarding the effect of these factors on the load-torque
relationship are provided in EPRI TR-111472, Assembling Bolted
Connections Using Spiral-Wound Gaskets [11].
7.2.3 Providing for Consolidation
Packing consolidation can reduce the gland stud load. It is, therefore,
important to repeatedly stroke the valve stem and torque the nuts until
there is no further nut rotation at the final specified torque. Each stroke
should be at least equal to the height of the packing.
To ensure that this important step is not missed, many plants include a
minimum number of stroke and tightening cycles. At least approximately
five cycles is suggested for typical braided packing sets. Deep packing
sets, double-packed valves with lantern rings and leakoff ports, and small
valves with large packing cross sections typically increase the difficulty of
achieving consolidation and may require more stroking and torquing
cycles. The best approach for these cases is often to consolidate small
groups of rings as they are installed.
66
7.3
Stem Friction
Historically, stem friction has typically been estimated as 1,000 lb/in.

(18,000 kg/m) of stem diameter. However, this simple estimate ignores
many factors that have a significant effect on stem friction, including:
67
Type of packing used (PTFE vs. graphite or carbon fiber)
Number of packing rings (short packing depth vs. large packing depth)
Applied gland preload force (low preload force/stress vs. high preload
force/stress)
Stem surface finish (rough vs. smooth finish)
Presence of live loading (live load vs. no live load)
Type of motion (that is, rotational, rising stem, and rising and rotating
stem)
The following equation captures several of these fundamental factors:

Fs
[Sg Y] [ Ds H] L
7-5

Gland Preload
where
Fs
Sg
Y
Ds
H
L
68
=
=
=
=
=
=
=
stem friction force (lb)

friction coefficient between stem and packing
axial gasket preload stress = gland preload stress, Pg
ratio of radial to axial stress in packing
stem diameter (in.)
packing height (in.)
load factor
The first term in the equation () is the friction coefficient between the
packing and stem; the second term (Sg Y) is the radial packing stress on the
stem; the third term ( Ds H) is the surface area of the packing in contact
with the stem; and the last term (L) is a measure of how well the load is
applied to and maintained on the packing during service.
The friction coefficient typically varies between 0.05 and 0.15 depending
on the packing material, stem material, stem surface finish, and whether
the friction is static or dynamic. The friction coefficient can be obtained
from the packing supplier or by test under actual plant conditions.
The ratio of the radial to axial stress in the packing (Y) is a function of the
packing material, number of rings, stem and stuffing box surface finish,
and shape of the packing (square vs. wedge). Reported values range from
0.50 to 0.85.
The load factor (L) is primarily a function of how well the torque is
converted into preload force and how well the gland load is maintained by
either live loading or periodic retorquing. Reported values range from 0.75
to 1.00. However, the preload can be as little as one-third of the desired
preload if the threads are not in good condition, there is poor lubrication,
or there is galling between the nut and follower.
69
This stem friction model illustrates the main principles to be applied in

reducing stem friction for a given application:
Keep the length of the packing short.
Keep surface finishes smooth.
Use packing materials with inherently low friction. However, loss of

blocking material in lubricated braided products can lead over time to
increased in-service consolidation.
7-6

Gland Preload
7.4
70
71
Live Loading
As a valve is stroked, the packing consolidates or wears so that the

packing axial and radial stresses decrease with time and cycles as shown
in Figure 5-3. This increases the potential for leakage past the stem. The
most important step to minimize this effect is to properly consolidate the
packing during assembly. However, for important applications involving
significant cycling during service, proper initial consolidation can be
supplemented by live loading the packing. The most common method of
applying live load is to install Belleville washers between the follower and
nut as shown in Figure 7-3. Alternative live loading arrangements are
shown in Figure 7-4.
Figure 7-3
Live Loading Using Belleville Washers
7-7

Gland Preload
Figure 7-4
Alternative Live Loading Configurations [7]
72
Figure 7-5 shows how Belleville washers act to maintain the load as the
packing consolidates or wears. With live loading, significantly more inservice consolidation can occur before the axial packing compressive
stress drops below the level at which leakage will occur.
7-8

Gland Preload
Figure 7-5
Effect of Live Loading on Valve Gland Stress [7]
Many users have believed that live loading is a cure-all that will solve
most packing leakage problems. However, live loading should only be
considered as an additional level of assurance after other precautions have
been followed. The sole purpose of live loading should be to
accommodate small amounts of service-induced consolidation.
73
While many valves could be live loaded, a more practical approach is to

live load valves based on cause. Typical candidates for live loading
include:
Critical and problem valves
AOV and MOV valves
Valves that are in high-vibration or high-cycle operation
Valves with deep stuffing boxes
Inaccessible valves that cannot be retorqued in service
One utility that has been an industry leader in developing a sound valve
packing program has applied live loading to approximately 150 out of the
total 12,000 packed valves at their two plants. This represents
approximately 1.25% of the total packed valve inventory.
7-9

Gland Preload
74
75
76
Vendors can provide recommendations for live load spring stacks for
various applications. EPRI NP-5697, Valve Packing Improvements [7],
also provides guidance for sizing spring packs. Key points from the EPRI
recommendations are as follows:
The ideal spring stack should have four to eight washers in order to
provide reasonable stroke, although success in some cases has been
achieved with as few as two Belleville washers.
Washers should be selected so that the target gland axial load is 70

80% of the spring manufacturers reported flat load.
The spring stack must be designed so that the spring washers will not
hang up on the stud threads. It may be necessary to use guides as
shown in Figure 7-6 to prevent interference.
Figure 7-6
Live Loading Spring Packs [7]
7-10

Gland Preload
77
7.5
Diagnostics
Diagnostic testing performed on AOVs and MOVs can provide useful

information regarding the packing condition. For example, a decrease in
stem friction force may indicate a loss of gland preload and the potential
need to retorque the gland studs. Similarly, an increase in stem friction
force may indicate extrusion or loss of lubricant in braid rings.
Over the past five to six years, a close correlation has been demonstrated
between the stem friction as calculated by formulas similar to those
described in Section 7.3 and actual values measured via MOV or AOV
diagnostic equipment in the field.
Once an expected value is established, measurements of stem friction will
indicate whether the actual value is higher or lower than predicted. If the
measured stem friction is at either extreme when compared to the
predicted value, the potential for valve problems will increase.
If packing loads are too high:
Air-operated valves may not stroke
Motor and air-operated valves may operate outside their design

range
Manual valves may be too difficult for operators to manipulate
Valve seating force may be so reduced that valves leak internally
Valve packing may wear excessively
Valves may bind up (gland follower galling on valve stem)
If packing loads are too low:
Valve packing may leak
Valve packing may not have been properly tightened
Valve packing may not have been properly consolidated
Packing studs or nuts may be galled
Packing stud lubrication may not be adequate
A review of stem friction obtained from more than 200 MOV diagnostic
tests at one plant were compared to the predicted stem friction. In all cases
where the measured stem frictions were significantly lower than the
calculated value, packing leaks developed. A review of additional testing
and data has found that the correlation between measured and predicted
stem friction continues to be accurate, generally within 1020%. Some
sites now require that valve packing be retorqued when the measured stem
friction drops below approximately 70% of the predicted valve. This drop
in friction is generally indicative of a loss of gland preload stress.
7-11

Gland Preload
If during MOV or AOV diagnostic testing, stem frictions are found below
the calculated values, the packing is either torqued to increase running
loads within the acceptable range or a detailed specific review is
performed. This review should consider:
Past test data from this valve and identical valves
Consequences of valve leakage
System pressure
Valve packing history
Until the accuracy of the stem friction formula had been confirmed, the
only measure of proper packing load was inferred from the torque value
applied to the packing studs. As has been noted in EPRIs bolt torquing
research, numerous factors can affect the actual load developed by the
bolts so that the actual applied load can be as little as one-third of the
desired load. Measurement of stem friction during the MOV or AOV
testing is a more direct measurement of the actual load on the packing.
78
7.6
Gland Design
Poor gland design can result in the applied preload force not meeting
expectations. The main causes of these losses are friction caused by
cocking of the gland and excessively tight clearances. The causes and
several possible solutions are described in Sections 7.6.1 through 7.6.5.
7.6.1 Gland and Follower Design One- vs. Two-Piece
Valve manufacturers have not standardized on the design parameters of
the gland and follower. Some vendors use a one-piece cast gland and
follower but most provide a two-piece gland and follower.
The apparent advantage of the two-piece gland and follower is that it
appears to be self-aligning, so that if the nut on one side is tightened more
than on the other side, the follower will rock and the gland will be
unaffected. Although this design does accommodate some mismatch in
bolt-to-bolt tightening, it provides the mechanical technician with no
practical means to straighten cocked glands, which is a major cause of
stem damage. With a one-piece design as shown in Figure 7-7, by
tightening on one side and loosening on the other, a slightly cocked gland
can be straightened.
7-12

Gland Preload
Figure 7-7
Potential Gland Follower Improvements [10]
7.6.2 Gland Length

Problems with deep stuffing boxes have already been described. The main
concern here is that if the deep stuffing box is filled with packing, it can be
difficult to achieve the proper initial consolidation and there may be
excessive in-service consolidation.
For valves with long glands, there is a tendency to add extra packing, or to
cut the bushing longer than is necessary, to provide extra take-up for
future retorquing. This can cause several problems:
More packing is used than is necessary
Increased potential for initial and service-induced consolidation
Higher-packing running loads then necessary
Potential for the gland cocking and scoring the valve stem
Short followers such as shown in Figure 7-1 have very little stuffing box
penetration and tend to cock more easily and score valve stems. A longer
gland will perform better provided that it can be accommodated by the
valve yoke area. For the case of short glands, it is also difficult to provide
for packing consolidation and to ensure that there is adequate take-up for
future valve retorquing.
7.6.3 Gland-to-Stuffing Box Clearance
The clearance between the gland and the stuffing box is critical. If the
clearance is too small, a little corrosion buildup or dirt can cause the gland
to stick in the stuffing box and not transmit the gland nut force to the
packing. If the clearance is too large, the gland can cock, score the valve
7-13

Gland Preload
stem, or become jammed in the stuffing box. In the past, many

manufacturers did not pay close enough attention to this area. Most major
valve manufacturers currently provide the correct tolerances for this area.
Clearances suggested by the MSS are provided in Section 5 of this report.
7.6.4 Gland Machining Practices
Glands are often supplied with sharp inside corners that may come into
contact with the stem. These sharp corners should be broken or machined
to produce a smooth radius.
7.6.5 Gland Materials
For situations where stem scoring has been a problem, glands can be
modified to provide a soft metal (brass) insert as shown in Figure 7-7.
7.7
Summary
Most packing should be preloaded to approximately 4,000 psi (28

MPa) to achieve proper initial consolidation and to provide margin for
service-induced consolidation. Higher gland preloads typically serve
only to increase friction and possibly damage fibers in graphite braid
anti-extrusion rings.
Equations for the preload torque necessary to produce the desired

preload stress are given.
It is important to ensure that the bolting is in good condition so that the

specified torque results in the desired gland preload. Factors include
thread condition, lubrication, and condition of the nut-to-follower
interface surface. Hardened steel washers should be installed between
the gland nut and follower surface to minimize friction losses at this
important location.
Packing should be consolidated by stroking the stem and torquing the

nuts until there is no further nut rotation. Many plants specify a
minimum of five cycles to ensure that this important step is not
missed.
Many applications require low stem friction. This is best achieved by

keeping the packing length as short as possible, using low-friction
coefficient packing materials, and maintaining smooth surface
finishes.
Live loading should not be viewed as a cure-all for packing leakage.

Rather, it should be viewed as a final step to provide an additional
level of assurance after all other precautions have been followed.
7-14

Gland Preload
Results of AOV and MOV testing can be used to assess packing

preload and the potential for leakage.
Attention should be paid to gland design and machining tolerances,

which have the potential to cause binding that will result in the force
on the gland being applied to the packing.
7-15
DEMONSTRATIONS USING VALVE

PACKING PERFORMANCE
DEMONSTRATION UNIT
80
81
82
83
This section describes experiments that can be conducted to demonstrate

valve packing principles.
8.1
An objective at the outset of this training program was to supplement

classroom instruction with experiments using packing materials and gland
configurations typically encountered in the field. Figures 8-1 and 8-2 show
the EPRI VPDU, which was designed to facilitate the experimental part of
the training. The completed VPDU is shown in Figure 1-1.
84
8-1

Demonstrations Using Valve Packing Performance Demonstration Unit
Figure 8-1
Valve Packing Performance Demonstration Unit (VPDU)
8-2

Figure 8-2
VPDU Packing Assembly and Valve Stems
85
The VPDU consists of a 0.75-in. (1.91-cm) stem that is sealed by packing

and is stroked into and out of the VPDU by a servo-controlled linear
actuator. The packing is installed in a 1.25-in. (3.18-cm) diameter stuffing
box that is preloaded by a follower and two 0.50-in. (1.27-cm) straingauged gland studs. The stem load is measured by a load cell between the
actuator and stem. The packing is pressurized by nitrogen to 100 psi (0.7
MPa) and the end of the stem opposite from the packing is sealed by
double oil-lubricated o-rings. Stem load and follower loads are monitored
by the load cell and strain-gauged bolts as the stem is stroked through up
to a 3-in. (7.62-cm) travel. Leakage of nitrogen from the packing is
monitored by a flow meter for leakage rates in the range of 0.1010
standard ft3/min (0.0028320.283 m3/min), and by the pressure decay
method for leakage rates less than 0.10 standard ft3/min (0.002832
m3/min).
8-3

The VPDU is designed to accept any packing that is intended for a 0.75in. (1.91-cm) stem and 1.25-in. (3.18-cm) stuffing box. The VPDU
includes three interchangeable stems as shown in Figure 8-2:
86
87
88
One with a smooth (4 inch [0.10 meter]) RMS finish
One with a rough (62 inch [1.57 meter]) RMS finish
One with a smooth finish, but tapered to simulate a thermally-induced

taper of 0.003 in. (0.008 cm) (produced by 400F [204.44C]
temperature difference) over a 4-in. (10.16-cm) stroke length.
The VPDU can be used to perform experiments that illustrate the effects
of key parameters on leakage, consolidation, friction, and wear. These
include:
Packing materials and design
Packing length
Packing preload
Live loading
Stem material
Stem surface finish
Stem straightness and thermal taper
8.2
Initial EPRI VPDU Experiments
The first use of the VPDU was at the August 2000 Fluid Sealing
Technology Program Working Group meeting. Attendees at this meeting
participated in performing tests on four different packing material
configurations with several different levels of consolidation for one of the
configurations. The procedure used for each test was as follows:
89
The packing was installed in the VPDU.
The packing was loaded to an axial gland stress of 3,000 psi (21 MPa)
by torquing the gland nuts to the specified value.
If specified, the packing was consolidated by stroking and torquing

five times.
The packing chamber was pressurized to 100 psi (0.7 MPa) with
nitrogen and the pressure decay after three minutes was recorded. The
pressure drop provides an indication of the initial packing tightness.
The stem was stroked in and out through a 1-in. (2.54-cm) stroke
length 20 times over an additional three-minute period.
8-4

90
The stem friction force was measured in both directions during the
stroking.
The pressure in the chamber and the pressure drop from the initial 100
psi (0.7 MPa) after 20 strokes were measured.
Results of the experiments are reported in Tables 8-1 and 8-2. These tests
showed the following:
91
Under nitrogen pressure, packing with die-formed flexible graphite

rings produced a tighter seal than braid rings only.
92
The tightest seal was achieved for the case involving a single dieformed graphite seal ring. This suggests that at least one die-formed
graphite ring can significantly reduce leakage as compared to using
only braid rings.
With the die-formed graphite seal rings: 1) composite backing rings

produced the lowest friction, 2) PTFE-lubricated graphite braid rings
produced intermediate friction, and 3) pure graphite braid rings
without filler produced the highest friction.
For the case of PTFE-filled graphite braid ring packing, 1) no

consolidation produced the greatest leakage and lowest friction, 2) five
strokes of consolidation produced intermediate leakage and friction,
and 3) five stokes of consolidation plus live loading produced the
lowest leakage and highest friction.
8-5

Table 8-1
Initial VPDU Experimental Results
<======= Same Set of Packing (just retightened) =======>
Packing Configuration
ZZZZ
ZZZZ
ZZZZ
X000
CC00
Z0Z
Initial Consolidation
No Consolidation
5 Strokes
5 Strokes + Live
5 Strokes
5 Strokes
5 Strokes
Force
(lb)
Pressure
(psi)
1st Consolidation Stroke

2nd Consolidation Stroke
3rd Consolidation Stroke
4th Consolidation Stroke
5th Consolidation Stroke
Starting Pressure (psi)
After 3 Minute Wait
After 20 1 Strokes
Stroking Friction
Total DP over 6 minutes +
20 cycles (psi)
Z = braid rings with PTFE
X = braid rings without filler
C = composite rings
0 = die-formed graphite rings
8-6
Force
(lb)
Pressure
(psi)
Force
(lb)
Pressure
(psi)
1780
1830
1840
1900
1970
Force
(lb)
Pressure
(psi)
------1460
1700
Force
(lb)
Pressure
(psi)
1800
1970
2020
2090
2130
Force
(lb)
Pressure
(psi)
1670
2110
2270
2340
2380
1900
100
95
1910
99
94
2130
98
94
1690
98
97
2130
99
97
2340
99
98
1460
260/-230
89
245
1790
360/-300
91
325
1740
360/-310
92
335
1580
425/-375
96
400
2060
300/-250
97
275
2160
375/-325
98
350
11

Table 8-2
Summary of Initial VPDU Experimental Results
Packing
Configuration
Consolidation
Average
Friction
Force (lb)
Pressure Drop From

100 psi Over 3 Minutes
and 20 - 1 Cycles
ZZZZZ
None
+/-245
11
ZZZZZ
5 Strokes
+/-325
ZZZZZ
5 Strokes + Live Load
+/-335
X000X
5 Strokes
+/-400
CC00C
5 Strokes
+/-275
Z0Z
5 Strokes
+/-350
These tests were performed solely to demonstrate valve packing

principles. They do not represent expected performance under operating
pressure and temperature conditions. Users are encouraged to contact
packing suppliers and test laboratories for more complete packing tests
performed under prototypical operating conditions.
8.3
Summary
Experience with EPRI leakage reduction training programs has shown

that hands-on experiments are important to convey important
principles and overcome incorrect preconceived notions.
A VPDU has been developed to facilitate training. The VPDU displays

stem friction, gland bolt force, and leakage as the stem is stroked.
Experiments with the VPDU have demonstrated the importance of

consolidation and differences in performance between packing
products.
8-7
VALVE PACKING INSTALLATION

PROCEDURES
This section describes the steps of installing valve packing for typical
applications. In some cases, these typical steps may be superseded by
vendor-specific requirements.
9.1
94
95
96
Valve Packing Procedure
The main steps in valve packing are described in Sections 9.1.1 through
9.1.8.
9.1.1 Remove Old Packing
Prior to disassembling packing, the as-found conditions should be
assessed. This should include inspections for evidence of current or prior
packing leakage and boric acid corrosion of any low-alloy steel parts in
PWR plants.
The gland nuts and gland studs should be checked for signs of galling and
poor lubrication.
After removing the gland nuts, the gland can be pulled from the stuffing
box, ensuring that it does not cock as it is being removed. After removal it
is sometimes useful to tie the gland out of the way so that it does not
interfere with repacking.
The old packing can be removed using standard packing hooks or pullers
or specialized equipment such as hydraulic tools. Care should be exercised
to not damage the stem or stuffing box during removal. The packing
should be inspected as it is being removed to ensure that the proper
materials had been used when last packed. If a lantern ring or graphite
bushing has been used, these parts should also be removed using packing
removal tools if the parts have been tapped. If the parts have not been
tapped, it may be necessary to use hydraulic packing removal tools or
shim stock in combination with stem movements to aid in removal. The
final step should be to confirm that all of the old packing has been
removed. This can be accomplished using tools and mirrors.
9-1

Valve Packing Installation Procedures
Finally, packing materials should be disposed of according to plant

procedures. Special precautions may be specified for packing that contains
asbestos or packing that is contaminated.
97
9.1.2 Inspect Valve

The amount of inspection is a function of the criticality of the application,
experience with the component, and the type of packing being installed.
For less critical applications where there is no history of leakage problems,
a visual inspection of the parts is generally acceptable. These inspections
should include stem, stuffing box walls, bushings, lantern rings, and gland.
The parts should be cleaned so that when reassembled it will appear as if
the valve has been repacked. This cleaning will ensure that leakage that
occurred in the past is not interpreted as new leakage in the future.
For leaks from more important valves, the inspections should be directed
toward finding the root cause of the leakage. In the vast majority of cases,
normal wear is not a useful root cause that will lead to resolving the
problem. Inspections should include inspecting the bottom of the stuffing
box, inspecting for stuffing box taper, and inspecting for misalignment. If
the packing has extruded, the diameters of the stem, stuffing box, and
gland should be measured to ensure that the clearances between the parts
are as specified. Figures 5-5 and 5-6 provide suggested tolerances.
For important applications where leakage has occurred, or where
composite end rings will be used, dimensional measurements are
warranted. These should include the diameters of the parts plus the slope
and angle of the stuffing box, and flatness of the bottom of the stuffing
box. Figures 5-4 through 5-6 provide suggested tolerances.
Specific inspection requirements should be included in the work orders for
critical or problem valves.
98
9.1.3 Prepare Bolting

Gland studs and nuts must be in good condition to develop the desired
preload force. Threads should be free of damage, burrs, rust, and paint.
Special attention should be paid to the seating surface between the bottom
of the nut and the top of the gland follower. Questionable parts should be
replaced.
Hardened steel washers should be used between the bottom of the gland
nuts and the top of the follower to minimize galling at this important
9-2

location. In many cases, valve vendors did not include hardened steel
washers.
In some cases, studs will have been permanently stretched due to
excessive preload. Stretching a stud increases the pitch between the
threads, leads to internal interference between the stud and nut threads,
and results in a lower load for the same applied torque. Thread pitch can
be easily checked by running the nut down the portion of the threads that
will be engaged during assembly. If the nut runs freely, the threads have
not been excessively stretched. If the nut binds, it is possible that the stud
has been permanently stretched and should be replaced.
Finally, the threads and the interface between the nut and follower should
be lubricated with an approved thread lubricant.
99
9.1.4 Obtain New Packing Components

The specified valve packing set should be obtained and independently
verified relative to the valve packing worksheet. This should include
performing any specified dimensional measurements, especially if the
packing set includes bushings and/or composite end rings. It should also
be confirmed that there will be at least one rings worth of take-up after
final consolidation to provide for future retorquing.
Gloves should be worn during packing assembly to ensure that the
packing is not contaminated.
100
101
9.1.5 Install Packing

The packing rings should be coated with the specified lubricant.
The packing parts should be assembled in the order specified on the
worksheet. Splits in adjacent rings should be offset by 90 to reduce the
potential for leakage. A graphite washer can often aid in assembling the
parts.
For important or problem valves, or for valves with lantern rings or deep
stuffing boxes, it is important to install and consolidate packing in steps.
Packing pushers can be used to assist in installing and consolidating
packing rings. It is especially important not to tighten packing unless all
rings are within the stuffing box.
9-3

102
9.1.6 Consolidate Packing

Unless otherwise specified, the valve packing should be consolidated by
stroking the stem and tightening the gland nuts until there is no further nut
rotation.
The nuts should be tightened equally on both sides to ensure that the gland
remains properly aligned.
The valve stem should be stroked at least five times with the nuts
retorqued after each stroke. After the five mandatory cycles, the stem
should be stroked and the nuts torqued until there is no further nut
rotation. It is only necessary to stroke the full height of the packing set
because most consolidation occurs due to a change in stroke direction.
Additional consolidation cycles are likely to be required under the
following conditions:
103
All braid ring packing sets (braid rings require more consolidation than
die-formed graphite or composite rings)
Double-packed valves with lantern rings and leakoff ports (the lower
sets of packing should be installed and consolidated before installing
and consolidating the upper sets of packing)
Small valves with large packing cross sections
9.1.7 Apply Live Loading if Used

The best practice is to consolidate the packing as described prior to
installing the live load package. Upon completion of the initial
consolidation, the gland nuts are removed, the surfaces of the specified
live load package lightly coated with the specified anti-seize lubricant, and
the live loading packages installed on the studs. The gland studs should
then be tightened to the specified torque, ensuring that the gland alignment
is maintained.
It should be confirmed that the live load spring pack has been compressed
to 7080% of full compression. If the specified preload torque produces
less than approximately 70% compression, the live load springs are likely
too stiff and they will not follow service-induced consolidation. If the
specified preload torque produces more than approximately 80%
compression, the live load springs are likely too soft and they will not
maintain the desired force following service-induced consolidation.
9-4

104
9.1.8 Periodic Retorquing

Ideally, the procedure described in this section should result in valve
packing that remains tight without the need for periodic retorquing. In
some cases, however, service-induced consolidation occurs due to either
relaxation of the packing due to time-at-temperature or valve stroking. In
these cases, it is desirable to periodically retorque the packing.
Procedures should be established that permit the packing to be retorqued
periodically as needed throughout the packing life with as little red tape
as possible. This can be best accomplished by pre-approved procedures.
For applications where retorquing is not possible, consideration should be
given to using live loading that will serve the same function. However, it
should not be necessary to hot torque a valve that has just been
maintained, and the packing consolidated, after taking it up to operating
conditions.
Nut rotation that occurs during periodic retorquing should be logged on
the valve data sheets. This information should be evaluated to identify
trends and should be used to determine the need for changes, such as the
desirability of installing live loading, during the next repacking.
9-5

9.2
105
Overview of Key Installation Steps
Figure 9-1 shows many of the key steps and precautions in valve packing.
Figure 9-1
Summary of Key Valve Packing Points [10]
9.3
Valve Packing Tips
Appendix A is training viewgraphs including descriptions of several valve

packing tips that may be useful, including:
106
9-6
For small valves, it may be preferable to prepare prepacked bonnets

prior to the outage and to replace the entire bonnet. The old bonnets

can then be repacked prior to the next outage. This approach will
minimize radiation exposure and foreign material exclusion concerns.
Lantern rings are often difficult to remove. Solutions to this problem

include:
Eliminate lantern rings where possible
Use tools to engage drilled and tapped holes in the lantern rings
Stroke the valve stem in an attempt to loosen the lantern ring
Shim the lantern ring to the stem and then stroke the stem to free
the ring
107
Remove the leakoff port and attempt to push and pry the lantern
ring through the port
108
Use a hydraulic packing removal tool to get water pressure

underneath the lantern ring
While installing packing sets that have split bushings, use thin flexible
graphite washers to hold packing sets together.
Efficiency can be improved, and the potential for errors reduced, if

packing sets are preassembled. Preassembled packing sets can be
purchased from packing suppliers. Alternatively, a utility can purchase
packing materials in bulk and assemble packages from the bulk parts.
Utilities should determine the best approach on a plant-specific basis.
Packing pushers should be used to consolidate packing in difficult

applications including valves with short-gland followers and doublepacked valves.
Some valves require special precautions to maintain valve stem

alignment during packing. If alignment problems are encountered,
solutions may include match-marking parts, and checking stem
alignment with shims during assembly.
Two-piece packing glands are intended to prevent imposing bending

moments on the gland during assembly. However, as described in
Section 7.6, this feature also prevents the application of more load on
one of the gland studs to straighten the gland. The solution in this case
may consist of using a one-piece gland.
Another technique is to ensure a thin piece of metal (shim stock) can

easily slide between the gland and stem as shown in Figure 9-2. As the
packing is tightened, continued checks will ensure that not only that
the gland stays in alignment but the total alignment of the assembled
valve is maintained.
For valves with short glands, the glands can sometimes cock, thereby
scraping the stem. Possible solutions in these cases are to add bronze
bushings at the top and bottom of the gland and to add a chamfer on
109
110
111
9-7

the leading edge of the gland as shown in Figure 7-7. In marginal

situations, the packing must be totally consolidated before the final
packing ring can be installed. Such steps add significantly to the time
and radiation exposure of this task. If it is attempted to install all of the
packing at once, the top ring may be above the top of the stuffing box.
As the gland is loaded, the unrestrained portion of the top ring may
tend to push outward. As the gland enters the stuffing box, it will cut
the pushed out packing material, shearing its fibers and jamming
packing between the gland and the stuffing box.
Figure 9-2
Use of Shims to Ensure Gland Alignment [10]
9.4
Summary
Guidance is provided regarding the main steps in valve packing:
Removal of old packing
Valve inspections
Preparation of bolting
Installation of packing
Consolidation of packing
Application of live load (if used)
Periodic retorquing
Figure 9-1 illustrates the most important factors in valve packing.
Several valve packing tips are provided.
9-8
10
VALVE PACKING IMPROVEMENT

PROGRAMS
113
114
This section describes aspects of valve packing improvement programs

that have proven successful at several plants. Information on overall
leakage reduction programs is provided in EPRI TR-114761, Establishing
an Effective Fluid Leakage Management Program [15].
10.1 Establishing Program Goals

The first step in a valve packing improvement program is a realistic
assessment of past and present valve packing experience. This should
include experience with packing leaks and the effort expended on
repacking. Information is provided in EPRI TR-114761, Establishing an
Effective Fluid Leakage Management Program, about overall leakage
reduction program goals and the overall leakage objectives for three
categories of applications: most important, intermediate importance, and
least important [15].
The assessment should be followed by identification of areas where
program improvements can and should be made. Ideally, engineering and
maintenance should jointly assess performance and identify where
improvements can be made.
Once potential program improvements have been identified, engineering,
maintenance, and management should work together to establish realistic
program goals that take into account leakage reduction objectives and the
true cost (maintenance time, engineering/management time, on-line leak
injections, value of lost production, and risk of lost production) of ongoing
leakage. The goals should be specific rather than general and could
include, for example:
Fewer than 10 packing leaks per year in the categories of most

important and intermediate importance applications
No on-line injections to stop valve packing leaks
A certain percentage reduction in valve packing leak repair cost
No plant shutdowns or power reductions due to valve packing leaks

10-1

Valve Packing Improvement Programs
An average valve repacking time of less than five man-hours per valve
Finally, a knowledgeable individual should be appointed to implement the

program. This individual can be from engineering or maintenance.
Qualifications are described in EPRI TR-114761, Establishing an
Effective Leakage Management Program [15].
115
10.2 Selecting a Packing Supplier

In most cases it is desirable to work closely with a knowledgeable packing
supplier. This supplier can help to:
Create an effective valve packing management program
Prioritize valves for rework
Identify the best packing products for the range of plant applications
taking into account plant-specific preferences and requirements
Establish an effective inventory program that minimizes the number of

special packing products and therefore cost
Provide test results and field experience for packing products
Provide contacts to other plants that have experienced problems with,

or developed solutions for, specific applications
Provide quick turnaround for special packing needs to minimize

required inventory without the potential for incurring lost production
Provide on-site assistance during outages
Assist in resolving problems
Provide training
References from other plants that have developed successful valve

packing programs should play a key role in the selection process.
Attention should be directed toward both the company that will provide
the packing materials and the individuals who will be providing home
office engineering and field support at the plant.
116
10.3 Selecting a Packing Product Strategy

A goal should be to establish a packing strategy that will provide the
greatest success with the least overall cost.
A suggested packing strategy is described in Section 6.3. The final
strategy worked out with the selected supplier should be both technically
sound and cost effective.
10-2

117
10.4 Creating a Database of All Valves

Plants typically have thousands of valves with many differences in design,
materials, tolerances, loads, and wear. One approach to managing this type
of variety is to create a database that describes each valve individually.
While valves can be sorted by vendor, model number, and size to review
packing performance, and make across-the-board changes, each valve can
also be reviewed individually for special considerations such as equipment
condition or unusual operating requirements. The individual who prepares
the work package as well as the maintenance technician will both have
identical information that will reduce the potential for errors that can result
from searching for data in a generic table.
The database entry for each valve should include:
Valve design information
Key valve dimensions (for example, stuffing box, stem, and gland)
Valve packing configurations and materials
Preload and live loading requirements
Valve operating experience (that is, leaks, leak rates, and repairs)
Retorquing experience
Valve maintenance history
Other relevant notes
The database entry could include information such as a note that next time
the valve is repacked the stem, gland, and gland studs/nuts should be
replaced, or that if the packing leaks, the torque should be increased to a
specified higher value.
The selected packing supplier should be able to assist in creating and
populating the database.
118
10.5 Prioritizing Valves for Rework

With thousands of valves in a plant, it is not practical or cost effective to
immediately repack all valves according to the new program. Accordingly,
it will be necessary to establish a strategy for implementing the new
program in a cost-effective manner.
For example, one approach would be to focus on valves in the following
order:
Problem valves
10-3

Special program valves (that is, local leak rate test boundary, 89-10
MOVs, and AOVs)
EPRI Category I valves (most important)
EPRI Category II valves (intermediate importance)
EPRI Category III valves (most important)
The first three of these groups are likely to have the greatest economic
impact because increased integrity for these valves will reduce the risk of
expensive repairs and possible lost production.
Other factors in the prioritization could include replacing packing when
the valve is being serviced for other purposes, replacing packing in all
valves of one type, and replacing packing in all valves in one system or
area of the plant. These factors will result in improved efficiency by
working one type of valve, or valves, in close proximity.
The selected packing supplier should be able to assist in prioritization
efforts.
119
10.6 Providing Training

Program development, prioritization, scoping, and planning will not result
in valves being properly packed. The program must ensure that the valves
are packed by trained and motivated technicians. The training should:
Be directed toward the products being used
Reflect the latest knowledge regarding the root cause of packing

failures
Include hands-on practice with the products to be used in the field
Include lessons learned and a review of recent problems
The selected packing supplier might be able to provide training materials,

or to provide useful input to a utility-developed training program.
Finally, buy-in by the maintenance technicians is essential. Impediments
to improvement in this regard are attitudes such as:
I already know all there is to know about valve packing.
Anyone can pack a valve.
This isnt my normal type of work.
10-4

120
10.7 Work Planning

Work planning is an essential part of an effective valve packing program.
Time must be spent on efficiently generating work packages and
scheduling the work. Alternative approaches include:
Working on all of the valves in one area
Working on all of the valves on one system
Working on all valves of a common design
Working on valves already being disassembled for other purposes
A valve packing datasheet can provide important information to the

technician, including packing materials, bolt torques, consolidation
procedure, past history, and special problems involving the specific valve.
Use of the datasheet minimizes the need for long procedures in the field
and also provides information that will be useful in the future when
addressing the issue of staff turnover.
An approach successfully used at one utility was to have all of the
important valves packed by one or two crews that specialized in this work.
This approach built team spirit and ensured that the person or persons who
performed the work are known throughout the plant.
121
10.8 Technical Support

It is important for engineers, work planners, and valve packing
coordinators to be available in the field, especially as the program is
initiated. This affirms the importance of the work performed and can serve
to detect poor work practices or problems before they become widespread.
As the program develops, and the work planners and technicians take
greater responsibility for the work, the level of engineering oversight can
typically be reduced.
122
123
10.9 Monitoring and Periodic Retorquing

Valve leakage should be monitored during periodic walkdowns. Leaking
valves should be retorqued as appropriate. Results of the walkdowns and
retorquing should be recorded in the valve database for future reference
and planned preventive maintenance.
The condition of packing in AOVs and MOVs should be assessed based
on stem friction measured during performance testing. Criteria should be
10-5

established for when retorquing and preventive maintenance should be

performed.
Finally, a program should be established for periodic retorquing of valves.
Table 10-1 is a retorque schedule developed by a BWR plant that is
reported to have small numbers of leaks. A sample plant-specific plan is
provided in Appendix B. These retorquing programs are intended for use
at plants that have already implemented a successful valve packing
program that results in few leaks. It is not intended as a plan to retorque
large numbers of leaking valves.
10-6

Table 10-1
Valve Retorque Schedule Used at BWR Plant With Reported Small Number of Leaks
MOVs Covered by Diagnostic Testing

Critical AOVs
Accessible High
Pressure/Temperature
BOP Valves
Accessible Low
BOP Valves
X
X
Other Critical and Problem Valves Identified by

Engineering
Valves Inaccessible During
Operation
Comments
Every Outage
Every Other
Outage
Every 34
Outages
Preventive Retorque
10 Year
Intervals
Leak During
Operation
Leak During
Outage
AVO Dag Test

Results
Retorque Based on Cause

VOTES Test
Results
Valve Type/Application
Retorque only as specified by

diagnostic test procedure

AOV drag tests
Retorque as specified by
engineering
Manual Valves
MOVs
Manual Valves
MOVs
Manual Valves
MOVs
Critical tested MOVs and AOVs are

only retorqued based on results of
diagnostic tests. There is no need for
periodic retorquing.
Critical and problem valves identified

by engineering are retorqued as
specified.
Non-problem inaccessible or high
temperature and pressure valves
should be retorqued in response to
leaks, and preventively retorqued every
34 outages to minimize risk of leaks.
Accessible light-duty manual valves

need only be retorqued in response to
leaks.
X
Accessible light-duty MOVs should also

be retorqued every 10 years.
Notes:
- Leak checks should be performed at the start of each outage at the highest possible system pressure
- Leak checks should be performed at the end of each outage with emphasis on valves that have been repaired
- Recommendations are for a plant where few leaks are expected due to following sound practices
- Recommendations are intended to maintain leak tight integrity, not to prevent leaks from large numbers of poorly packed valves
- Results of inspections and retorquing should be recorded on valve datasheets to identify the need for future maintenance and the need for retorque on similar valves.
10-7

124
10.10 Root Cause Analysis and Feedback

Finally, it is important that lessons learned in the field be factored back
into the program so that conditions that cause leaks are not repeated in the
future. The valve packing coordinator or valve engineer should be
involved in the root cause evaluation for all packing leaks in important
valves, and these results should be fed back into the packing program to
prevent similar problems in the future.
Engineers have stated in EPRI leakage reduction workshops that they do
not have time to get involved in the root cause evaluation of all leaks.
However, if the program is effective, the number of leaks will be small,
and there should be ample time to participate in root cause evaluations.
10.11 Summary
It is important to have a valve packing program with specific and

realistic goals. Possible goals are provided.
The packing program should be developed in close cooperation with a

selected packing supplier.
A packing product strategy that results in achieving the desired results

at the least cost should be developed.
A database of all packed valves is a useful approach to dealing with

the large number and variety of applications. This approach allows for
rapid reviews of similar applications with easy access to clear
information regarding valve specific details.
A program to prioritize valves so that repacking is performed in a

timely and cost-effective manner should be developed.
Individuals performing valve repacking activities should be trained in

the best methods for reducing packing leaks, the products being used,
and recent problems and lessons learned. The training should ideally
include hands-on practice.
Engineers, work planners, and valve packing coordinators should be

available to detect poor work practices and to assist in root cause
evaluations for problem valves.
A schedule should be developed for periodic retorquing of valve gland

studs.
10-8
11
OVERVIEW
In the final analysis, leakage reduction from valve packing depends on a

few key technical and programmatic fundamentals:
11.1 Technical Fundamentals
Pure graphite packing sets with die-formed flexible graphite seal rings
and plain braided end rings (X000X) should form the core of a plants
valve packing program. The die-formed flexible graphite rings provide
excellent sealing, and the absence of lubricants and blocking materials
in the plain braid rings minimizes the potential for service-induced
consolidation.
High-density graphite spacers and bushings should be included below,

and in many cases above, the packing to reduce the packing height in
deep stuffing boxes, to center the stem, and to take any side loads.
Cushion and junk rings should be used below the spacer to provide
proper support to the spacer, especially for cases involving stuffing
boxes with an angled bottom surface. The basic packing configuration,
therefore, should become (BX000XSW).
For applications requiring lower friction, the number of die-formed

flexible graphite seal rings can be reduced to two, or possibly even
one; square rings can be replaced with reduced-height rectangular
rings; and the plain graphite braid rings can be replaced by lubricated
braid rings or wire-wrapped graphite tape rings (BZ00ZSW) or highdensity composite rings (BC00CSW).
For some lesser importance low-temperature and pressure applications,

all lubricated braid ring packing can be used (BZZZZSW).
A gland preload of 4,000 psi (28 MPa) should typically be used to

provide proper initial consolidation and margin for typical problems
such as poor stem finish, tight clearances, and some service-induced
consolidation.
The bolting materials must be in good condition, well lubricated, and a

hardened steel washer provided between the gland nut and follower. If
these precautions are not followed, the actual applied preload is likely
to be less than the desired preload.
11-1

Overview
All valve packing must be torqued. The valve must be stroked

repeatedly (at least five times) and the gland nuts torqued each time
until there is no further nut rotation. At this point, the valve packing
will be properly consolidated.
Live loading (Belleville washers) should be used for critical or

problem valves that cannot be retorqued in service or for cases
involving high-density composite end rings that provide little
compliance.
Properly installed packing will result in predictable stem friction. Stem

friction should be monitored on AOVs and MOVs to ensure that
specific valve packing is properly preloaded and to ensure that the
overall packing program is producing anticipated results.
A program of periodic valve packing retorquing should be established.

Properly designed, installed, and retorqued packing should seldom
require repacking. If repacking is required, then the root cause should
be determined to identify required changes to the valve packing
program to prevent recurrence. If a valve is simply repacked using the
original materials and procedure, it is likely that it will leak again.
11.2 Programmatic Fundamentals
Management should provide support including the establishment of

realistic program goals for leak-tight integrity and overall cost
(including cost of repairs and lost production due to leaks).
A packing management program should be established that results in

valves being repacked in a cost-effective manner that meets program
goals for leak-tight integrity and cost.
An experienced packing supplier should be selected who is able to

provide the required packing as well as needed home office and field
assistance to establish a packing program and troubleshoot problem
applications.
Up-to-date procedures should be prepared that reflect the best current

technologies to achieve high-integrity valve packing at a reasonable
cost.
Technicians should be trained to follow procedures but to be alert for

possible problems.
A progressive and systematic approach should be established to deal

with the few remaining leaking valves.
11-2
12
REFERENCES
1. Valve Application, Maintenance, and Repair Guide. EPRI, Palo Alto,
CA: 1999. TR-105852-V1.
2. Boric Acid Corrosion Guidebook. EPRI, Palo Alto, CA: 1995. TR104748.
3. Boric Acid Corrosion Guidebook, Revision 1. EPRI, Palo Alto, CA:
2001. 1000975.
4. U.S. Nuclear Regulatory Commission. Assessment of Pressurized
Water Reactor Primary System Leaks. NUREG/CR-6582, 1997.
5. Valve Stem Packing Improvement Study. EPRI, Palo Alto, CA: 1982.
NP-2560.
6. Valve Stem Packing Improvements. EPRI, Palo Alto, CA: 1986. NP2455.
7. Valve Packing Improvements. EPRI, Palo Alto, CA: 1988. NP-5697.
8. Grafoil Brand Flexible Graphite Engineering Design Manual, Volume
1, Sheet and Laminate Products. Union Carbide Corporation, 1987.
9. Radiation Data for Design and Qualification of Nuclear Plant
Equipment. EPRI, Palo Alto, CA: 1985. NP-4172SP.
10. Photographs and figures provided by K. Hart of PPL Susquehanna,
LLC.
11. Assembling Bolted Connections Using Spiral-Wound Gaskets. EPRI,
Palo Alto, CA: 1999. TR-111472.
12. Manufacturers Standardization Society of the Valve and Fittings
Industry, Inc. Flexible Graphite Packing System for Rising Stem Steel
Valves (Design Requirements). SP-120, 1997.
13. Control Valve Packing Systems. Technical Monograph 38. Fisher
Controls International, Inc., 1992.
12-1

References
14. Manufacturers Standardization Society of the Valve and Fittings

Industry, Inc. Qualification Testing Methods for Stem Packing for
Rising Stem Steel Valves. SP-121, 1997.
15. Establishing an Effective Fluid Leak Management Program. EPRI,
Palo Alto, CA: 2000. TR-114761.
12-2
TRAINING SLIDES
The viewgraphs are to be used for classroom instruction. They are linked to the full report text
for further information.
A-1
EPRI
Plant Leak Reduction Training
Valve Packing Performance

Improvement
Objective
! The objective is to help nuclear plants reduce the number and severity of
leaks from valve packing
! This objective will be accomplished by providing a better understanding
of the key factors that contribute to valve packing performance:
How valve packing works

The types of packing available and where they should be used
The required packing gland preload
The role of consolidation in long-term packing performance
The importance of live loading for valves that are cycled
Major causes of packing leaks
! Instruction will be supplemented by experiments using a VPDU
Valve Packing Performance Improvement: 2
Contents
! Valve Packing Concepts
! Industry Experience With Valve Packing Leaks
! Valve Packing Products
! Causes of Valve Packing Failures
! Selecting Packing Configurations and Products
! Gland Preload
! Experiments Using VPDU
! Valve Packing Procedures and Tips
! Valve Packing Improvement Programs

Methods of Sealing Valve Stems
! Valve stems are either sealed or packed
! Sealed valve stems:
Bellows-type seals
Diaphragm-type seals
O-rings
! Packed valve stems:
Packing rings
V (Chevron) packing

Methods of Sealing Valve Stems (cont.)

Converting Packing Axial Stress into Radial Stress
! Packing creates a seal as follows:
Valve packing is inserted into a stuffing box in the

valve bonnet
An axial load is imposed on the packing by a gland
that is in turn loaded by torquing gland nuts
The axial load on the packing causes the packing to
expand outward, creating radial seals at both the
stem and stuffing box
! Several key technical concerns are:
The radial load on the stem produces friction that

must be overcome during valve operation
The packing must be prevented from extruding out
through the gaps
Consolidation or creep during service may result in
loss of axial load and hence radial load
Industry Experience With Valve Packing Leaks

Summary of Industry Experience
! Valve packing has been, and continues to be, a main source of
leaks in nuclear plants
! Significant progress has been made in understanding the causes
of valve packing leaks, and this knowledge has resulted in
significant reduction in leaks from critical valves
! Some plants have significantly reduced leakage from all valves
by a pro-active packing management program
! Other plants continue to have many packing leaks from less
critical valves

Recent EPRI Analysis of Leaks at Two Plants
S o urc e o f
Le ak
To tal
WO's
To tal
WO's
Plant A
Plant B
Ave rag e
WO's
Pe rc e nt
Ave rag e WO
Man-Ho urs fo r
Plant B
pe r Ye ar
pe r Unit
Fla nge d J oints
a nd Ga s ke ts
850
189
69
23%
32
P ipe a nd Tube
Fittings
500
359
57
19%
31
Va lve P a cking
663
563
82
27%
16
S e a ls
302
220
35
12%
24
Othe r
263
620
59
20%
69
Tota l
2,578
1,951
302
100%
38*
Va lve P a cking Wa s S ingle La rge s t

S ource of Le a ks From
1995 Through 1999
*This total is generated from more information than is presented in this table.

Recent EPRI Analysis of Leaks at Six Plants

Sources of Leaks per NUREG /CR-6582

Histogram of Reported Leaks per NUREG /CR-6582
Valve Packing Products

Evolution of Valve Packing
! Asbestos braid packing
(until mid-1970s)
! Non-asbestos braid packing
(starting mid-1970s and still used for some applications)
! Die-formed graphite rings with braided anti-extrusion rings
(starting early 1980s and still in use)
! Fully engineered die-formed graphite packing system
(starting late 1980s and still in use)

Braid-Type Seal Rings (non-asbestos still in use)

Die-Formed Graphite Seal Rings (both types in use)

Typical Parts of Engineered Packing System

Typical Parts of Engineered Packing System (cont.)
! Belleville washers (optional):
Provide uniform load to compensate for some in-service consolidation

Useful for problem valves, critical valves, and cyclic duty valves
Must be properly designed to meet functional requirements
! Bushing (optional):
Fabricated from high-density graphite

Acts to center bent or misaligned stems
Prevents side loads from being transmitted into packing
! Anti-extrusion rings:
Die-formed seal rings require backup rings to prevent extrusion

Braid rings do not involve tight tolerances but can add significant friction unless
lubricated
Composite rings require tighter tolerances but add minimal friction

! Die-formed flexible graphite seal rings:
Provide the primary seal

Are fabricated from die-formed flexible graphite
Are split for assembly onto stem
Typically only two or three rings are required
Rings can be square, rectangular (compact), or wedge-shaped (see Slide 22)
! Spacers:
Fabricated from high-density graphite

Split for assembly onto stem
Take up unnecessary space in stuffing box to reduce packing height
-
Minimizes consolidation
Reduces friction
Act to center bent or misaligned stems

Prevent side loads from being transmitted into packing

! Cushion ring (optional):
Might be required if bottom of

stuffing box is rough or not square
Prevents cracking of bottom edge
of hard spacer
Can be braid ring or flexible
graphite washer
-
Braid ring can produce higher friction than

washer
! Junk ring (optional):
If the bottom of the stuffing box is

machined at an angle, a metal or
high-density graphite junk ring
may be necessary to produce a flat
surface for the packing assembly

Design and Performance of Wedge-Type Packing
! Wedge-shaped die-formed
flexible graphite rings are
designed to provide:
Better transfer of axial gland stress

to radial packing stress
Better sealability at lower gland
packing pressures
Figures from
EPRI NP-5697
! However, experience shows that

all die-formed packing requires
about the same 4,000 psi gland
preload to ensure proper
consolidation and margin against
loss of load during operation

Typical High-Pressure Valve Without Live Loading

Commercial Products Survey
! The table on Slides 25 and 26 displays the major packing
products offered by three major suppliers to nuclear plants as
determined by a survey of Fluid Sealing Technology Program
members:
Other vendors also supply valve packing products

The vendors listed also provide other products not included in the table
! The table presents the functions of the various products relative

to the requirements for an engineered packing system
! Users are encouraged to obtain complete and current
information on the latest products, including applicable test
results, directly from the suppliers or independent test labs

Commercial Products Survey (cont.)
Product Type
Alternative Products
Positive Features
Die-Formed Graphite
Packing Rings
Square or Rectangular Rings Excellent sealing

Low friction
Low consolidation
Excellent sealing (low gland stress)
Note: All die-formed rings Wedge Shaped Rings
Lowest friction (low gland stress)
are susceptible to
Low consolidation
extrusion
Anti-Extrusion
Graphite Yarn Ring
Low cost
Rings
Low halogen
High Density Die-Formed
Low friction
Graphite
Low consolidation
Spacers and Bushings
Washers
Composite Ring
Graphite/Resin
Lowest friction
Low consolidation
Solid Graphite Rings Split

for Assembly
Contribute to better seal

Contribute to lower friction
Bushings take side loads
Low cost
Aids in assembly
Cushions bottom of spacer
Graphite Sheet Rings
Negative Features
Tolerance sensitive
Tolerance sensitive
Consolidation
Increased friction
Gland stress limited to 4-6 ksi
Tolerance sensitive
High cost and increased inventory
Tolerance sensitive
Increased cost and inventory
Bushings tolerance sensitive
Extra cost and inventory
Argo
Chesterton
Garlock
6300 J
5200
5300
GRAPH-LOCK
Rings
5800
9000-EVSP
includes various
end ring types
One
One-CI
G-700
5600
GRAPH-LOCK
Rings
524
6000
5005 std density
5010 high density
6200 N
N/A
5100
4525
N/A

Commercial Products Survey (cont.)
Product Type
Alternative Products
Positive Features
Negative Features
Argo
Chesterton
Garlock
N/A
N/A
Braided Packing
Rings
Asbestos Yarn
Graphite/Mica Filler
Not applicable since no longer being

installed
Health hazard
Hardening in service
N/A
Note: All braid type

packing is susceptible to
consolidation
Graphite Fiber Yarn

Graphite BA/Lube
Low cost
Low halogen
Low cost
Low friction
Low cost
Low halogen
Low cost
Low friction
Low cost
Low halogen
Low cost
Low halogen
Low cost
Low friction

7300
N/A

525
G-200
526
N/A
5000
#98
Graphite Fiber Yarn

PTFE BA/Lube
Carbon Fiber Yarn
Graphite BA/Lube
Carbon Fiber Yarn
PTFE/Graphite BA
Graphite Tape
High Temp BA
Graphite Tape
Wire Reinforced
Graphite Tape
Wire reinforced
PTFE BA/Lube

Needs braid end ring for >1200 psi
Potential leakage
Wire reinforcement
Wire reinforcement
7000
1400
GRAPH-LOCK
Tape
7300-I
1601
1398
1399
7301-I
1600
1303-FEP
Causes of Valve Packing Failures

Summary List
! Low gland stress
! Packing consolidation
! Dimensions and clearances
! Stem and stuffing box surface finish/corrosion
! Stem misalignment
! Stem thermal taper
! Product misapplication and aging
! Excessive friction

Low Gland Preload
! Sufficient gland preload must be applied to:
Properly consolidate (compress) the packing

Provide for in-service consolidation and wear
! Gland preload is typically applied by torquing the gland nuts.

However, several factors can result in the specified torque not
producing the desired preload. For example:
Rusted or deformed gland studs

High friction between the nut and follower
! These conditions can be avoided by:
Use of clean studs/nuts

Good lubrication at threads and between nut and follower
Smooth contact surfaces between nuts and follower (use hardened steel washers if
possible)

Packing Consolidation
! Packing must be compressed axially during installation to consolidate
(compress) the material and create a seal:
Seal to the stem

Seal to the stuffing box
Seals between the packing layers or strands and at the packing cut ends
! The required axial compression is a function of packing type:
Braid ring packing must typically be compressed 2550%

Die-formed graphite rings (90 lb/ft3) typically compresses less than 20%
Experience has shown preload should generally be about 4,000 psi
! The packing may leak if
Packing is not properly consolidated during assembly

Additional consolidation occurs in service due to voids created internal to the
packing due to extrusion, wear, and loss of blocking material

Packing Consolidation (cont.)
! Test data shows that dieformed graphite at a
density of (90 lb/ft3) will
consolidate less than 20%
at a gland pressure of
4,000 psi
Figure from EPRI NP-5697

! Friction between the packing and stem and stuffing box results in less axial
compressive stress at the bottom of the packing than at the top. Under this
condition:
The top of the packing can be properly consolidated

The bottom of the packing can contain voids due to incomplete consolidation
! The axial load in the packing will become more uniform with time:
This will reduce the maximum radial load that produces the seal
! This is a greater problem with:
Deep stuffing boxes (greater depth of packing not fully consolidated)

Braided-type packing (has more voids so requires greater consolidation)
High-friction packing or rough stem surface (greater falloff of axial stress with depth in
packing)

Figure from EPRI NP-5697


! Best approaches to ensure proper
initial consolidation are:
Use a packing that requires less

consolidation and has lower friction
Reduce packing height
-
23 die-formed graphite rings

5 braided rings
Cycle valve stem in and out during

assembly, torquing the gland nuts after
each cycle until there is no further
gland nut rotation (at least five cycles)
! Reduced packing height also serves

to mitigate in-service consolidation

Part Dimensions and Clearances
! Poor clearances between parts can lead to binding or excessive gaps at
the following locations:
Stem to gland
Gland to stuffing box
Stem to bonnet
Anti-extrusion ring to stem and stuffing box
Spacer to stem and stuffing box
Top bushing to stem and stuffing box (if used)
! Binding can cause high friction and wear between metal parts
! Excessive gaps can cause:
Extrusion of materials leading to loss of gland preload

Wedging of packing in the gaps leading to high friction

Part Dimensions and Clearances (cont.)
! Engineered packing systems with high-density components,
such as spacers, bushings, composite anti-extrusion rings, and
high-density anti-extrusion rings, require special attention:
They provide better performance (less leakage, better consolidation, less

friction) when properly selected and installed
They require more effort to specify and assemble than a simpler braid ring
type packing system, which is less susceptible to tolerances
The parts are stiffer and have less compliance to follow small motions
during operation
-
Live loading may have to be applied to compensate for reduced compliance

Running Tolerances and Clearances
! MSS Standard Practices SP-120, Flexible Graphite Packing
System for Rising Stem Steel Valves (Design Requirements)
provides the following tolerances and running clearances

Stuffing Box Tolerances
! MSS SP-120 provides the following tolerances for packing
chambers (stuffing boxes)

Stem Tolerances
! MSS SP-120 provides the following tolerances for stems

Stem Surface Finish
! The stem surface must be smooth in order to create a good seal, minimize
friction, and minimize packing wear
! MSS SP-120 specifies that the stem surface shall be:
32 Ra (microinch) or better
Free of scratches, pits, or voids deeper than 0.002 inches
! Union Carbide states that a 32 Ra surface is acceptable for hand-operated

valves but a 16 Ra surface is better for control valves
! Fisher Controls Monograph 38 reports that their control valve stems are
polished to a surface finish of 4 Ra or better
! If there are questions regarding surface finish, the surface finish should be
checked by a comparator

Stuffing Box Surface Finish
! The stuffing box must also have a good surface finish to allow
the packing to compress with minimal resistance during
installation
! While MSS SP-120 does not include requirements for stuffing
box surface finish, a finish of 32 Ra or better should be
achievable for this surface
! MSS SP-120 specifies that the stuffing box shall be free of
scratches, pit, or voids deeper than 0.006 inches

Corrosion
! Corrosion of valve stems is detrimental to the surface finish, and is
especially a concern with graphitic packing materials that are:
Cathodic with respect to the metal stems

Electrically conducting
! MSS SP-120 specifies that flexible graphite packing shall contain:
A dispersed passive corrosion inhibitor

A dispersed embedded active corrosion inhibitor
A suitable combination of inhibitors to minimize stem pitting
! Galvanic corrosion is most likely to occur during storage conditions with

high humidity and moisture left over from hydrostatic testing:
Some utilities remove packing from valves to be stored

This approach ensures that valve will be packed properly when installed

Corrosion (cont.)
! MSS Standard Practices SP-121, Qualification Testing Methods for
Stem Packing for Rising Stem Steel Valves, specifies that corrosion
tests shall be performed on packing systems. The test cell is
illustrated below. Test conditions and acceptance criteria are
specified in MSS SP-121

Stem Misalignment
! Stem misalignment can result in:
Lateral loads on the packing that can potentially open up a gap between
the stem and the packing
Contact between the stem and gland that can cause wear and degrade the
stem surface finish
Wedging of the gland on the stem so that the gland load is not applied to
the packing. This is often a problem for valves with short glands

Stem Misalignment (cont.)
! The effects of misalignment can be
mitigated by including graphite
bushings at the top and bottom of
packing set
! The bushings will keep the stem
centered in the packing and take
side loads

Stem Thermal Taper
! When a valve operates hot, the part of the
stem deep in the valve is typically at a higher
temperature than the outer part of the stem
! Due to thermal expansion, the hotter part of
the stem is at a larger diameter than the colder
part of the stem
! Thermal tapers for typical valve stem
materials are:
About 0.0006" per inch of stem diameter per 100F

for carbon and martensitic stainless steels and typical
nickel alloys
About 0.0009" per inch of stem diameter per 100F
for austenitic stainless steels

Stem Thermal Taper (cont.)
! As a hot stem is withdrawn from the
valve, the packing is expanded
radially to accommodate. This
produces additional consolidation of
the packing
! As the stem cools or is reinserted
into the valve, a potential leak path
can be created
! For severe conditions, live loading
has the potential to compensate
somewhat for the changes in
packing volume

Misapplication of Packing Products
! Packing leaks can result from a poor choice of packing products for the
application. Several examples are presented
! PTFE (Teflon) packing has a high coefficient of thermal expansion relative to
typical steel valve materials. This results in 1) increasing packing loads as the
temperature increases, 2) extrusion of the PTFE at high pressures, and 3) gaps
formed in packing upon cooling. Coefficients of thermal expansion are:
Carbon and martensitic stainless

Austenitic stainless steel
about 7x10-6 in/in/F

Graphite packing products

PTFE packing products
about 15x10-6 in/in/F (through thickness)


Misapplication of Packing Products (cont.)
! Virgin PTFE experiences
high creep above about
100F
! PTFE decomposes at
temperatures higher than
about 500F
! Vendors have reported good
experience using PTFE as a
lubricant/blocking material
in braided packing at higher
temperatures

Misapplication of Packing Products (cont.)
! Graphite fibers in graphite yarn braid material tend to fracture at
gland stresses above about 4,000 psi:
However, there should seldom be a need to exceed 4,000 psi gland stress
! Graphite bushings or spacers are hard and can crack if unevenly

supported at the bottom of the stuffing box (see Slides 21 and 22)
! Engineered packing assemblies require relatively tight clearances
and may require additional installation effort in valves with large
clearances or tapered stuffing boxes

Excessive Friction
! Many applications require low or repeatable friction for proper functioning:
Hand-operated valves can be difficult to operate if friction is too high

AOVs and MOVs require low and reproducible friction
High friction forces can result in valves not seating and resultant internal leaks
! Low friction is achieved by:
Keeping packing height to a minimum

Minimizing contact on stem of anti-extrusion rings, bushings, and spacers
Using low-friction packing materials
Maintaining smooth stem surface finish
Adding PTFE (even if in small amounts) to packing assembly where technically
acceptable
-
Small amounts of PTFE dispersed in materials

Thin PTFE washers between assembly elements

Overview of Packing Options
! The ideal packing configuration would have the following
characteristics:
High, leak-tight integrity with low friction

Easy installation with no measurements or tight tolerances required
Only a few different parts required to be stocked
Low cost

Packing Coding System
! Many different packing
configurations are in use
! A coding system can be used to
designate the packing
configuration
! The coding system described is
a composite of systems used by
several utilities, but modified
slightly so as to not highlight
specific vendor products
Code for Typical 5 Ring Set

top
bottom
X000X
braided graphite rings
lubricated braid rings (that is, PTFE, graphite/oil)
die-formed graphite rings
composite anti-extrusion rings
high density anti-extrusion rings
graphite spacers
graphite bushings
flexible graphite washers

Suggested Basic Configurations
! The heart of a plant's valve packing program should be a standard
23 ring set of die-formed flexible graphite with braid-type
anti-extrusion rings (BX000XSW):
23 die-formed flexible graphite rings to provide the seal

Braid-type graphite anti-extrusion rings with no lubricants or blocking
materials that might cause consolidation because they are lost over time
High-density graphite spacers and bushings to keep the packing height to a
minimum, center the stem, and take any side loads
! If lower friction is required:
Use two die-formed flexible graphite rings

Use reduced height rectangular rings in lieu of square rings

Suggested Basic Configurations (cont.)
! If the standard set provides too much friction, then two main alternatives
should be pursued
! Replace plain braided graphite end rings with lubricated braided graphite
(BZ000ZSW):
Graphite or PTFE-lubricated braided graphite

-
May experience in-service consolidation as lubricant is lost
Braided wire-wrapped flexible graphite tape

-
Not ideal for cyclic duty applications due to increased stem wear
! Replace plain braided graphite end rings with composite end rings
(BC000CSW):
Composite end rings are very stiff and live loading may be necessary to compensate for
lost compliance

Suggested Basic Configurations (cont.)
! For less critical valves and less demanding service conditions
(typically, low-temperature water) it is possible to use all lubricated
braid ring packing (BZZZZZSW):
All-braid packing has greater potential for leakage than packing including dieformed flexible graphite rings
There is increased potential for not achieving the desired initial consolidation
and for increased service-induced consolidation
All-braid packing is likely to require more frequent retorquing and repacking
than systems with die-formed flexible graphite
All-braid packing may be easier for less skilled maintenance technicians to
install

Possible Approach to Inventory Optimization
! Stock die-formed flexible graphite rings, plain graphite braid rings,
low-friction lubricated graphite braid rings, graphite
bushings/spacers and graphite washers in standard sizes (that is,
0.75" x 1.25") and assemble the packages from the parts as needed
for each application
! Purchase fully engineered packages (and live loading if used) for
the most critical and problem valves as preassembled sets from the
supplier:
Preassembled sets ensure that the proper parts are used

Preassembled sets ensure that parts are in optimum condition

Evaluating Specific Products
! Users should evaluate products based on field experience and/or
qualification tests and then use the best products for the application:
Properly designed and installed packing should have a long life

Repacking valves represents a significant investment in time, cost, and radiation exposure
! MSS Standard Practice SP-121 specifies methods for qualification by

testing. This document covers:
Test fixtures and instrumentation

Test procedures
Test acceptance criteria including static vs. dynamic leakage
Corrosion tests
! Qualification test results should be obtained from vendors or independent

test labs
Gland Preload
Gland Preload
Required Gland Preload Stress
! EPRI NP-5697 suggests that most packing should be preloaded to:
1.75 x system pressure

For BWR plants this represents about 2,000 psi
For PWR plants this represents about 4,000 psi
! Field experience has shown that gland stresses of 2,000 psi may be too
low to ensure adequate consolidation and to provide margin for:
Less than ideal bolting conditions

Service-induced consolidation
! Therefore, a preload of 4,000 psi should be a goal for most

applications
Gland Preload
Required Gland Force
! The required gland force is the gland pressure times the gland cross section
area:
where
Fg = Pg [Do2 - Di2] / 4
Fg
Pg
Do
Di
=
=
=
=
required gland force

the required gland pressure
the gland outside diameter (stuffing box diameter)
the gland inside diameter (stem diameter)
! The equation can be simplified to:

Fg = 0.785 Pg [Do2 - Di2]
Gland Preload
Required Gland Nut Torque
! The required torque for the case where 1) the studs are in good condition, 2)
the nut-to-follower interface is smooth, flat, and hard, and 3) lubrication is
applied to the threads and to the nut-to-follower interface, is given by the "nut
factor" equation:
Tp = [Fg/N] K D / 12
where
Tp = required torque (ft-lb)

Fg = required gland force (see previous slide)
K = experimentally determined "nut factor"
0.16 for typical nickel- or graphite-based lubricants
D = stud nominal diameter (inches)
N = number of studs
Gland Preload
Required Gland Nut Torque (cont.)
! Combining the equations for preload force and torque, the following
expression is obtained for the typical case where there are two studs:
Tp = 0.00524 Pg [Do2 - Di2] D
! As previously noted, this depends on:
Good condition studs and nuts

Good condition threads
A smooth, flat, and hard surface between the nut and follower (hardened steel
washers)
Good lubrication of the threads and nut-to-follower surface
! It also depends on the gland not cocking and creating high friction
against the valve stem
Gland Preload
Required Gland Nut Torque (cont.)
! Significant preload can be lost by
friction (galling) at the interface
between the gland nuts and
follower:
Use hardened steel washers between the

nuts and follower
! Some valve suppliers have

provided soft steel washers that are
not significantly better than no
washer at all
Gland Preload
Stem Friction
! Historically, stem friction was estimated as 1,000 lb per inch of valve
stem diameter
! However, this is an oversimplification, because valve stem friction is
a function of several variables including:
Type of packing material used (braid vs. composite anti-extrusion rings)

Type of braid rings (plain graphite vs. PTFE- or graphite-lubricated)
Number of packing rings used (short vs. long packing depth)
Gland load applied to the packing
Stem surface finish (rough vs. smooth)
Presence of live loading (live load vs. no live load)
Type of stem motion (rotational, rising, rising and rotating)
Gland Preload
Packing Friction (cont.)
! Packing suppliers use variations of the following basic model to
calculate stem friction:
Fs = [Sg Y] [ Ds H] L
Load factor
Surface area of packing on stem
Radial packing stress on stem
where
Fs =
=
Sg =
Y =
Ds =
H =
L =
Friction coefficient
stem friction (lb)

friction coefficient between stem and packing
axial gasket stress (psi)
ratio of radial to axial stress in packing
stem diameter (in)
packing height (in)
load factor
Gland Preload
! The friction coefficient () typically varies between 0.05 and 0.15
depending upon the packing material, stem surface finish, and whether
the friction is static or dynamic
! The ratio of radial to axial stress in the packing (Y) is a function of the
packing material, number of rings, stem and stuffing box surface
finishes, and shape of packing (square vs. wedge). Reported numbers
range from 0.50 to 0.85
! The load factor (L) is typically in the range of 0.75 to 1.0, and a
function of:
How well the preload torque on the nuts is converted into preload stress on the
packing (with poor conditions the load can be 1/3 of desired load)
How well the gland load is maintained by either live loading or periodic retorquing
Gland Preload
! The stem friction equation illustrates the main principles to be
applied in reducing stem friction for a given valve design. These
are:
Keep the stem surface finish smooth

Keep the length of packing that applies radial load to the stem low
Use packing materials with inherently lower friction
-
However, materials that achieve low friction by use of lubricants have the potential for more
service-induced consolidation due to loss of the lubricant
! Vendors should be contacted for product-specific

recommendations based on test results for input to stem friction
calculations
Gland Preload
Live Loading
! Live loading consists of adding some type
of spring between the gland nuts and
follower to maintain a load on the packing:
Live loading is typically accomplished using

conical spring washers (Belleville washers)
! Many users believe that live loading is a

cure-all that will solve all valve leakage
problems
! In fact, live loading is best applied after all
other precautions have been observed:
Its sole purpose should be to accommodate any

final service-induced consolidation
Gland Preload
Other Live Load Configurations
Figures from Fisher Controls Technical Monograph 38
Gland Preload
Live Loading (cont.)
! Live loaded valves can
accommodate much
more consolidation
before a leak occurs
Gland Preload
When to Apply Live Loading
! All valves can be live loaded
! An alternative approach is to live load valves based on cause.
Typical candidates for live loading include:
Critical and problem valves

AOV and MOV valves
Valves that are in high vibration or high cycle operation
Valves with deep stuffing boxes
Valves that cannot be retorqued in service
! As an example, at one U.S. BWR plant that has had a successful

valve packing program for years, only about 150 out of a total of
12,000 packed valves are live loaded. This is about 1.25% of the
total packed valve inventory
Gland Preload
Sizing Live Load Packages
! Live load packages can be purchased from the packing supplier or
assembled by the utility based on data from EPRI and the Belleville
washer suppliers
! EPRI provides guidelines and two flow charts in NP-5697, Valve
Stem Packing Improvements, to design and specify live load
packages:
Figure 5-6 from NP-5697 is a flow diagram for selection of disc springs
Figure 5-7 from NP-5697 is a flow diagram for determining spring stack
specifications
! A simplified sizing approach is described on Slide 75
Gland Preload
Sizing Live Load Packages (cont.)
! Simplified sizing of live load packages
Ideal stack should have 48 washers to provide reasonable stroke

Size spring washers so that the target gland bolt load is 7080% of the
manufacturer's reported "flat load"
Match spring washer and stud material
The flat load of a washer can be doubled by using two washers in parallel
Gland Preload
Sizing Live Load Packages (cont.)
! Confirmation that the washers will not hang up on the stud threads is
necessary
! Belleville washers can be installed in guides if necessary
Gland Preload
Diagnostics
! A close correlation has been demonstrated between stem friction
measured in AOV/MOV testing and predicted friction:
Previously there was no method to determine how well the torque on the nuts was
converted to axial load in the packing
! This information should be used to assess packing performance:
If friction loads are too high

-
AOVs and MOVs may operate outside their design range

Valves may not seat properly and internal leakage can occur
Packing wear may be accelerated
Valves may bind up
If friction loads are too low

-
Valve packing might not have been properly consolidated

Valve packing might have experienced service-induced consolidation
Valve packing might leak
! Assessment results can be used to establish corrective action
Gland Preload
Gland Design
! Two-piece glands were designed to be
self aligning, yet a one-piece gland is
actually easier to keep in alignment:
A one-piece gland can be aligned by

tightening the bolt on one side of the follower
more than on the other side
! Short glands pose an increased risk of

cocking and stem damage (see Slide
65):
Break sharp machined edges at bottom edge

of follower
Use brass/bronze bushing in gland
Ensure that gland has proper clearance to
stuffing box (see Slide 37)
Experiments Using VPDU

Background
! Demonstrate principles of valve packing in a classroom environment:
EPRI leakage reduction training classes have highlighted the value of

demonstrating the principles using actual equipment
Without demonstrations, many experienced engineers and craft might continue to
apply outmoded practices and personal biases
! Simple experiments enhance understanding of packing fundamentals

and compare performance of different packings:
It is not the purpose of the VPDU to replicate the valve packing qualification tests
specified by MSS SP-121
It is useful to have the capability to readily perform experiments to demonstrate
specific packing-related issues and compare some performance features of
different packing products

VPDU Experimental Approach
! Demonstrate packing products under prototypical dimensional
conditions
! Pressurize packing with 100 psi nitrogen at room temperature:
Low pressure and temperature for portability and safety reasons
! Simulate different stuffing box and stem finishes, and thermal stem
taper
! Impose controlled speed, travel length, and numbers of cycles
! Monitor the following variables:
Gas leakage rate

Stem friction
Gland load

General Arrangement - Side View

General Arrangement - Front View

Packing Assembly - Plan View

Instrumentation and Control
! Process control:
Program #1
Program #2
Program #3
Program #4
Return stem to "home" (retracted) position

Extend stem out D inches (D cm) at V mm/sec
Cycle stem N times through D inch (D cm) stroke at V mm/sec
Set D (20100 mm, 75 mm nominal) and
V (15 mm/sec, 3 mm/sec nominal)
! Gland bolt load - by strain gauged studs

! Stem load (friction force) - by strain gauge load cell
! Leak rate:
Leak rates 0.110 SCCM - by mass flow meter

Leak rates <0.1 SCCM - by pressure decay method

Valve Stems
! Three interchangeable valve stems are provided to simulate a
range of possible operating conditions

Examples of Demonstrations to be Performed
! Several types of demonstrations can be performed:
Comparison of different packing materials under limited conditions

Effects of assembly practices on packing consolidation
Effects of cycling on consolidation, leak rate, and stem load
Effects of live loading (Belleville washers)
Effect of stem surface finish and thermal taper

Initial VPDU Demonstrations
! Initial demonstrations were performed using the VPDU at the
August 2000 Fluid Sealing Technology Program working group
meeting
! Demonstrations were performed to illustrate the effects of the
following variables on leakage and stem friction:
Packing configuration (number and type of packing rings)

Packing materials
Consolidation (consolidation strokes and live loading)

Initial VPDU Demonstration Procedure
! Packing was installed
! Packing was loaded to a gland stress of 3,000 psi (20.68 MPa)
and consolidated as specified
! Nitrogen pressure of 100 psi (0.69 MPa) was applied and then
the valve was closed locking in the pressure
! The valve stem was stroked in and out through a 1" (2.54 cm)
stroke 20 times over three minutes
! The stem friction force and pressure drop over the three minute
test were recorded

Initial Demonstration Results
<======= Sa me S e t of P a cking (jus t re tighte ne d) =======>
P a cking Configura tion
ZZZZ
ZZZZ
ZZZZ
X000
CC00
Z0Z
Initia l Cons olida tion
No Cons olida tion
5 S troke s
5 S troke s + Live
5 S troke s
5 S troke s
5 S troke s
Force
(lb)
P re s s ure
(ps i)
Afte r 20 1 S troke s
S troking Friction
Tota l DP ove r 6 minute s +
20 cycle s (ps i)
P re s s ure
(ps i)
Force
(lb)
P re s s ure
(ps i)
Force
(lb)
P re s s ure
(ps i)
Force
(lb)
P re s s ure
(ps i)
Force
(lb)
P re s s ure
(ps i)
1670
2110
2270
2340
2380
1800
1970
2020
2090
2130
------1460
1700
1780
1830
1840
1900
1970
1s t Cons olida tion S troke

2nd Cons olida tion S troke
3rd Cons olida tion S troke
4th Cons olida tion S troke
5th Cons olida tion S troke
S ta rting P re s s ure (ps i)
Afte r 3 Minute Wa it
Force
(lb)
1900
100
95
1910
99
94
2130
98
94
1690
98
97
2130
99
97
2340
99
98
1460
260/-230
89
245
1790
360/-300
91
325
1740
360/-310
92
335
1580
425/-375
96
400
2060
300/-250
97
275
2160
375/-325
98
350
11
Z = braid rings with PTFE

X = braid rings without filler
C = composite rings
0 = die-formed graphite rings

Summary of Initial Demonstration Results
Consolidation
Average Friction
Force (lb)
Pressure Drop From

100 psi Over 3 Minutes and
20 - 1" Cycles
ZZZZZ
None
+/- 245
11
ZZZZZ
5 Strokes
+/- 325
ZZZZZ
5 Strokes + Live Load
+/- 335
X000X
5 Strokes
+/- 400
CC00C
5 Strokes
+/- 275
Z0Z
5 Strokes
+/- 350
Packing
Configuration

Conclusions From Initial VPDU Demonstrations
! Under nitrogen pressure, packing with die-formed flexible graphite rings
produces a tighter seal than using only braid rings:
The tightest seal was achieved with single die-formed graphite ring
! With die-formed flexible graphite seal rings:
Composite backing rings produce the lowest friction

PTFE-filled braid rings produce intermediate friction
Braid rings without filler produce the highest friction
! With PTFE-filled braid ring packing (ZZZZZ):
No consolidation produces the highest leakage and lowest friction

5 stroke consolidation produces intermediate leakage and friction
5 stroke consolidation + live load produces the lowest leakage and highest friction
! Stem friction forces are reproducible
Valve Packing Procedures and Tips
Valve Packing Procedures

Basic Steps
! Remove Old Packing
! Inspect Valve
! Prepare Bolting
! Obtain New Packing Components
! Install Packing
! Consolidate Packing
! Install Live Loading (if used)

Remove Old Packing
! Assess as-found condition:
Identify presence of inactive leak

Identify any evidence of boric acid corrosion
! Remove packing gland nuts:
Check that gland nuts are not galled and were properly lubricated
! Remove gland, ensuring that it does not stick in stuffing box:
Tie gland out of the way if possible
! Remove old packing using appropriate tools:
Use standard packing hooks or pullers

Use specialized tooling such as hydraulic tools
Assess condition of packing as it is removed

Remove Old Packing (cont.)
! Confirm that all material has been removed from stuffing box
! Pull out lantern ring if installed. Removal methods include:
Use of packing tools if drilled and tapped

Use of shim stock and stem movement to aid in removal
Use of hydraulic packing removal tools
! Dispose of asbestos and/or contaminated materials per plant standards

! For important valves that were leaking, perform a root cause
evaluation and establish corrective action to avoid repetition:
The root cause is seldom "normal wear"

There is usually a specific technical cause that should be addressed

Inspect Valve
! Ensure that stuffing box is free from old packing, corrosion products, and
bushings
! Take and record all specified measurements
! Perform inspections (if necessary due to critical application or leaks)
Stuffing box shape (that is, slopes and angles) steam cuts and cleanliness
Stuffing box bottom surface (that is, angle, flat bottomed, and washer)
Fit of gland in stuffing box, damage, binding, and angle at bottom
Stem surface free of nicks, gouges, and corrosion
Stem alignment and change of alignment on backseat
! Clean valve
Valve should look like it has been repacked

Clean valve will better show future leaks

Prepare Bolting
! Stud and nut condition:
Threads free of damage, burrs, rust, and paint

Run nut down through active length of stud to check for stretched threads
(stud and nut pitch not the same)
! Follower surface should be free from galling

! Hardened steel washer should be used between nut and follower

Obtain New Packing Parts
! Obtain specified packing component parts
! Verify packing size and cross section
! Perform any dimensional measurements specified on valve
packing worksheet:
Confirm dimensions for valves with composite rings, high density end
rings, and bushings
Check that dimensions are compatible with packing to be installed
! Confirm that bushing length allows for at least one ring's worth
of take up after final consolidation

Install New Packing
! Wear gloves to ensure that packing is not contaminated
! Coat each braid ring with a light coat of specified packing
lubricant
! Install packing parts in the order specified on the datasheet:
Ensure no binding, overlaps, or excessive clearance

A graphite washer can serve to hold split bushing halves together during
installation
! Use a packing pusher to consolidate packing in steps:
Don't attempt to tighten packing which is sticking out of stuffing box

Install all packing rings with the splits separated by 90

Install New Packing (cont.)
! Fit gland into stuffing box:
Ensure that gland fits without binding

Use shim stock (if necessary) to ensure
that gland remains centered during
packing consolidation
! Assemble gland bolting:
Lubricate the stud threads, nut-to-washer,

and washer-to-follower surfaces with the
specified anti-seize lubricant
Note: Live loading package should not be
installed until after consolidation has been
completed

Consolidate Packing
! Torque gland nuts to the specified values in steps to ensure that the
gland remains properly aligned
! Consolidate the packing at final specified torque:
Stroke the valve stem a minimum of five times, retorquing after each stroke
Continue stroking and retorquing until there is no further nut rotation
It is only necessary to stroke the full height of a packing set (the biggest
consolidation occurs due to change in stroke direction)
Additional strokes may be required under several conditions
-
All-braid packing sets

Double-packed valves with lantern rings and leakoff ports (consolidate lower packing with a packing
pusher before consolidating the top packing)
Small valves with large packing cross sections (that is, Yarway design valves where the internals can
be removed through the stuffing box)

Apply Live Loading (if used)
! Apply light coating of anti-seize lubricant to all surfaces of the
live loading package
! Install live loading package
! Tighten gland nuts to the specified torque, ensuring that gland
alignment is retained
! Remove any shims centering the gland
! Confirm that spring pack has compressed to 7080% of full
compression

Periodic Retorquing
! Hot retorquing of newly installed and consolidated packing should not
be required
! Periodic retorquing during service is important (see Slides 122 and
123)
! A system should be established whereby the retorques to manual
valves can be performed with as little "red tape" as possible
! Best approach is to work out pre-approved procedures to retorque
valves during convenient opportunities
! Problems identified during the retorquing should be logged on the
valve data sheets

Overview of Key Packing Steps
Valve Packing Tips

Unpacking Small Bolted Bonnet Valves
! It is often easier to remove the bonnet bolts and push the
packing out than it is to remove the packing using hooks:
There is also less chance of damaging the stem and packing chamber
! Some utilities prepare repacked bonnets prior to the outage,

replace the entire bonnet, and repack the old bonnet during slow
periods prior to the next outage
Valve Packing Tips

Lantern Ring Removal
! The best approach is to eliminate the need for leakoff ports and
lantern rings entirely
! Several techniques have been developed for removing lantern
rings:
Stroke the valve and observe if the lantern ring follows the stem
Shim the lantern ring to the stem to determine if it will follow the stem
when stroked
Remove the leakoff port and attempt to push and pry the lantern ring free
Use a hydraulic packing removal tool to get water pressure underneath the
ring to push it out
If the end of the lantern ring is drilled and tapped, build fixtures to pull on
the ring
Valve Packing Tips

Graphite Washer to Hold Packing Parts Together
! A flexible graphite washer can be used under split bushings to
hold them together and in alignment as they are installed in
deep packing chambers:
The washer is not able to cock on the stem, thereby preventing the split
rings from dropping into the stuffing box
Valve Packing Tips

Prepackaging Valve Sets
! Prepackaging valve packing sets can increase efficiency in the field
and provide a check against making errors
! A utility can purchase packing materials in bulk and assemble
packages from the bulk products prior to the outage
! Alternatively, valve packing can be purchased as integrated packages
from packing suppliers:
These packages can include all of the necessary parts including die-formed rings,
anti-extrusion rings, bushings, washers, and live load washers (if used)
! There is an obvious tradeoff between the two approaches that is best

made on a plant-specific basis
Valve Packing Tips

Packing Pushers
! It is especially important to achieve good consolidation in:
Valves with short gland followers

Double-packed valves
! This often requires that packing be consolidated in stages as the

packing is installed
! Packing pushers are used to reach from the bottom of the gland
to the packing
Valve Packing Tips

Maintaining Proper Stem Alignment
! There are some cases where the manufacturing tolerances are
such that proper stem alignment is not maintained
! If this occurs, several precautions should be taken:
Do not pack valves until after assembly

Match mark parts and reassemble carefully
Check stem alignment with shims
High-density graphite bushings should be used above and below the
packing
! Misalignment can be checked as the gland is being tightened by

inserting thin metal shims between the stem and gland

General Content
! General leakage reduction programs are covered under a
separate module of the EPRI Fluid Sealing Technology
Program:
Establishing an Effective Fluid Leak Management Program, EPRI

114761
! The information in this training is limited to valve-specific

programmatic suggestions

Establish Program Goals
! Assess current valve packing program performance
! Identify where improvements can and should be made
! Establish specific program goals and a time schedule. For
example:
Fewer than 10 packing leaks per year

No packing injections
A certain percent reduction in valve packing leak repair expenses
Zero plant shutdowns or power reductions due to valve leakage
An average valve repack time of less than five man-hours per valve
! Appoint a knowledgeable person to implement the program

Select a Packing Vendor
! Work closely with a valve packing supplier, who can help to:
Create an effective valve packing management program

Prioritize valves for rework
Identify the best packing products for the range of applications taking into account
plant-specific preferences and requirements
Establish an effective inventory system
Provide test results and contacts to other plants with similar equipment and
problems
Provide quick turnaround for unique packing needs
Assist in resolving problems
Provide training
! Recommendations from other plants should play a key role in

selecting a vendor

Select Packing Product Strategy
! Several possible packing product strategies involve:
Fully engineered packages

Die-formed graphite rings with braid ring backup
All braid rings
Live loading
! An application and inventory strategy should be worked out

with the selected packing vendor:
The strategy should be technically sound

The strategy should be cost effective

Create a Database of All Valves
! With thousands of valves in each plant, a database covering each valve is
important to the implementation and management of an effective program
! The database should include:
Valve design information

Valve operating experience
Key valve dimensions (that is, stuffing box, stem, and gland)
Valve packing configuration and materials
Preload and live loading requirements
Retorque experience
Other relevant notes
! The packing vendor should be able to help in creating and populating the
database

Prioritize Valves for Rework
! It is not possible or economically attractive to rework all valves during a
single outage
! Possible prioritization includes:
Problem valves
Special program valves (LLRT boundary, 89-10 MOVs, AOVs)
Category I valves*
Category II valves*
* EPRI leakage reduction program categories
Category III valves*
! The first three of these groups will have the greatest economic impact
! For most valves, a good approach would be to replace the packing when the
equipment is being serviced for other reasons

Provide Training
! Program development, prioritization, scoping and planning will not get
valves packed properly. Training of technicians is crucial
! Training must:
Be directed towards the packing products to be used

Reflect the latest knowledge regarding the root causes of packing failures
Include lessons learned, including review of recent problems
! Packing vendors can often provide training materials and on-site training
! Support of technicians is essential. Problems frequently result when the
attitude is:
"Anyone can pack a valve"

"This isn't my type of work"

Work Planning
! Time must be spent on efficiently generating work packages and
scheduling work:
Work all valves in one area or system

Work all valves of a common design
Work valves already being disassembled for other purposes
! Communicate most information to the technician by a valve packing

datasheet:
Provides all necessary information in one place and in a standardized format

Minimizes the need for long procedures in the field
Minimizes the potential for mistakes
! Having one or two crews perform most valve repacking work improves
efficiency and encourages team spirit and pride

Technical Support
! A good program can be compromised by a few technicians who do not
understand the importance of factors such as consolidation or poor
stem finish
! While most technicians are conscientious, poor work practices can
develop over time
! At the start of the program, technical support people must be in the
field to ensure that the work is being performed correctly
! As the program develops, this responsibility can be transferred to
selected technicians, forepersons, or engineers
! The presence of knowledgeable technical support should pay for itself
in improved efficiency

Monitoring and Periodic Retorquing
! It is difficult to stop leaks once they have started:
Leakage can create paths through the packing materials similar to steam cutting of metal
flanges
Once leaks reach a certain point, retorquing may not be effective in stopping the leak
! Provisions should be made for regular retorquing of valves on a preventive

basis (see Slide 123)
! There should be no need for "hot torquing" immediately after packing a
properly consolidated valve
! For AOVs and MOVs, the performance of the packing can be monitored by
tracking the stem friction:
The data should be evaluated and a determination made if corrective action should be
performed
! The retorque schedule in Slide 123 has been used by a BWR plant with a
reported small number of leaks

Monitoring and Periodic Retorquing
MOVs Covered by diagnostic Testing

Critical AOVs
Every
Outage
Retorque as specified by
engineering
Manual Valves
MOVs
Accessible High
BOP Valves
Manual Valves
MOVs
Accessible Low
BOP Valves
Manual Valves
MOVs
Valves Inaccessible
During Operation
Every Other
Outage
Every 3-4
Outages

diagnostic test procedure
AOV drag tests
X
X
10 Year
Intervals
L eak During
Operation
Preventive Retorque
X
X
Other Critical and Problem Valves Identified

by Engineering
L eak During
Outage
AOV Drag
Test Results
Valve Type/Application
VOT ES Test
Results
Retorque Based on Cause
Comments
Critical tested MOVs and AOVs are only retorqued

based on test results of diagnostic tests. There is no
need for periodic retorquing
Critical and problem valves identified by
engineering are retorqued as-specified
Non-problem inaccessible or high temperature and

pressure valves should be retorqued in response to
leaks, and preventively retorqued every 3-4 outages
to minimize risk of leaks
Accessible light-duty manual valves need only be

retorqued in response to leaks
X
Accessible light-duty MOVs should also be

retorqued every 10 years
Notes:
- Leak checks should be performed at the start of each outage at the highest possible system pressure
- Leak checks should be performed at the end of each outage with emphasis on valves that have been repaired
- Recommendations are for a plant where few leaks are expected due to following sound practices
- Recommendations are intended to maintain leak tight integrity, not to prevent leaks from large numbers of poorly packed valves
- Results of inspections and retorquing should be recorded on valve datasheets to identify the need for future maintenance and the need for retorque on similar valves

Root Cause Failure Analysis and Feedback
! The root cause of packing leaks should be determined and
corrective action developed to prevent recurrence
! Results of the root cause analysis should be fed back into the
packing program to prevent similar problems on other valves
! If the total number of leaks is small, then there will be ample
time to perform the root cause analyses
SAMPLE VALVE PACKING SURVEILLANCE AND

RETORQUING PROGRAM
The attached program was developed by one BWR plant to provide guidance regarding valve
packing surveillance and retorquing.
B-1

Sample Valve Packing Surveillance and Retorquing Program
Table B-1
Sample Valve Packing Surveillance and Repacking Program (BWR Plant)
Reference Number:
Valve Packing
Packing-1
All Types of Valves with Packing
Criticality
Duty Cycle
(Continuous, Standby, Cycles, Loading)
Service Condition
(Temp., Vibration, Dust, Water Chemistry)
Group
Walkdown of
All Areas
Outside of
Containment
During Startup
ID(s)
No
components
attached
Item
Activity
Number
Description
Scope
Basic Information
Operations Rounds
Procedure
Operator Rounds
Operator Rounds are defined in Operations Rounds Procedure. See a detailed list
of inspection of the scope of this inspection in the associated PM Background
Information Document.
This activity is performed to address many

dominant failure modes. The performance interval
is in accordance with and based on Operations
Rounds procedures.
DA
D1
M1295-02
M1295-52
Walkdown Areas
Outside
Containment for
Leaks During S/U
Inspect for Leaks and Record Results. Be sure to use proper WALKDOWN MAPS
as attached to the Valve Packing Background Information Document (BID).
For Manual Valves:
If leaks are found:
This activity has proven to be successful at

eliminating or significantly minimizing plant
impacts from packing leaks over the past 15
years. This activity is performed during startup.
Graphite packing does not perform well after it
starts leaking. If not stopped, it will worsen. This
task is a good predictive tool for assessing
maintenance that was performed, how well things
were done, and what areas could use
improvement as in training, etc.
YR

years. This activity is performed during refueling
outage shutdown while still at pressure to insure
all leakage problems are identified so they can be
addressed during the outage.
YR
Retorque packing on manual leaking valves.
Since Unit is starting up, every effort must be taken to stop all identified leaks.
Follow guidance in MT-GM-011, and contact Foreperson/Engineering if leak
cannot be stopped, for consideration to increase torque values.
For MOVs and AOVs:
Report leaks to Maintenance Valve Lead Foreperson.
Lead Foreperson determine approval necessary to allow packing to be

adjusted appropriate Post Maintenance Testing (LLRT, VOTES, 6 Point, etc.).
If leak does not stop, contact Argo Rep. or MOV/AOV engineer to increase
torque higher and to evaluate Post Maintenance Testing.
Utilize the Valve Walkdown Datasheet (attached to the Valve Packing BID).
For all actions taken:
Walkdown of
Drywell During
Rx Shutdown
B-2
No
Components
attached
D2
M1297-01
M1297-51
Walkdown Drywell
During Reactor
Shutdown
Checking for Leaks
Document valves that were retorqued.
Measure amount of take-up on the gland and record any valves found within
minimal take-up.
Record number of flats turned.
Walkdown the Drywell and identify any leak such as packing, pressure seal and
bolted valve bonnet flanges that may be leaking.
Utilize the Valve Walkdown Datasheet contained in the Valve Packing BID
Every attempt should be made to perform walkdown at highest reactor

pressure possible.
Record valves that show signs of leakage.
Retorque packing on manual leaking valves, if advisable.
Measure amount of take-up on the gland and record any valves found with
minimal take-up or signs of leakage.
Torque any leaking flange connections per MT-GM-015, if advisable.
Torque Pressure Seal and Bolted Bonnet Fasteners per MT-GM-003, if

advisable.

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
Walkdown
Whole Unit
other than
containment
During
Shutdown
ID(s)
No
Components
attached
Item
D3
Activity
Number
M1296-01
M1296-51
Description
Walkdown Areas
Outside
Containment
During Shutdown
Checking for Leaks
Scope
Inspect for Leaks and Record Results. Be sure to use proper WALKDOWN MAPS
as attached to the Valve Packing Background Information Document (BID).
For Manual Valves, if leaks are found:
Retorque packing on manual leaking valves, if possible, to provide data to

evaluate repacking valve.
minimal take-up. Record number of flats turned.
Record results on copy of Valve Walkdown Datasheet (see Valve Packing

BID).
For MOVs and AOVs:
Record results on copy of Valve Walkdown Datasheet (see Valve Packing BID).
For all actions taken:
Walkdown
Hydro
Walkdown
Hydro
No
Components
attached
No
Components
attached
D4
D5
M1365-01
M1365-51
M1295-01
M1295-51
minimal take-up.
Record number of flats turned.
Record results on copy of Valve Walkdown Datasheet (see Valve Packing

BID).
Support Operations
Hydro SE-100-002
and other pressure
tests by Adjusting
MOV and AOV
Packing Leaks
when Required
Inspect for Leaks and Record Results on the Valve Walkdown Datasheet contained
in the Valve Packing BID.
Packing adjustments cannot be made without:
Support Operations
Hydro SE-100-002
and other pressure
tests by Torquing
Manual Valve
Packing and
Flange Leaks when
Required
Inspect for Leaks and Record Results on the Valve Walkdown Datasheet contained
in the Valve Packing BID.
Work being properly released by OPS.
Input from Engineering regarding Post Maintenance Testing (i.e., LLRT,

VOTES, AOV testing).
In general, the first packing adjustment will be made to the last torque value that the
packing was adjusted to in the past. Planning needs to include in the Work Package
a listing of the last torque value for all valves included in the OPS Hydro.
Attempt to stop leak by retorquing packing in accordance with MT-GM-011. If

attempt is unsuccessful, contact Engineering for approval to increase torque
per MT-GM-011.
Torque leaking flanges connections per MT-GM-015.
Torque pressure seal and bolted valve bonnets per MT-GM-003.

Planning should include generic packing torque values for small manual valves in
the work package.
Basic Information
years. This activity is performed every refueling
outage during shutdown while still at pressure to
ensure leaks in all critical areas of the plant are
identified. Walkdown maps provide a plan to
access areas at the highest pressure but lowest
radiation doses, for ALARA. Areas of the plant
that can be taken out of service without impacting
plant performance, such as Radioactive Waste,
are not inspected at this time.
YR

years. This activity is performed during
Operations hydro to ensure leak-tight
performance for the next operating cycle and to
verify Post Maintenance 0 leakage criteria.
YR

years. This activity is performed during
Operations hydro to ensure leak-tight
performance for the next operating cycle and to
verify Post Maintenance 0 leakage criteria.
YR
B-3

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
ID(s)
Item
Activity
Number
Description
Scope
Basic Information
Walkdown
Leak-off
Headers
V0507-01 is
Disc. Med.,
RTPM
No
Components
attached
D6
V0507-01
V0507-51
Walkdown All
Accessible LEAKOFF Headers
Determine at the leakoff headers any valves that are leaking.

Consider use of PdM acoustics and thermography to assist in determination.
Generate PCWO for all leaks identified.
Review results with Argo/Engineer to determine trends or special actions that should
be taken.
This activity identifies any valves within this

system that are leaking back to the condenser.
The frequency has been changed from 2 yr to 1 yr
with the intent that it be scheduled during the
summer following an RIO, to allow both
consistency in data collection to identify work for
the next upcoming RIO, and to confirm that valve
leaks addressed during the past RIO were
successful. Engineering is pursuing the
elimination of the leakoff system that requires
these valves to be double packed. Double-packed
valves are historically a problem for packing due
to difficulty in maintaining load due to the
excessive amount of packing and to proper
stroking due to the excessive loads. Once the
leakoff system is eliminated, this PM can be
canceled; until then all leaks cause some lost
thermal efficiency and indicate potential external
packing leak that could impact the valve operator
and area.
YR
Drywell
Manual Valves
2 diff.
Elevation
levels
No
Components
attached
DM
V0503-01
V0503-51
V0503-03
V0503-52
Retorque Valve
Packing for
Manual Valves in
the Drywell
Retorque packing of all manual valves in the half of the Drywell for this RTPM.
Document only the problem valves identified that are:
This activity has proven to be the least cost

approach to maintaining valves in the Drywell.
The performance interval was changed from 3 to
6 years in 1995 based on results of performance
reviews.
This RT is performed by dividing the Drywell in
half by elevation. The manual valves in one half of
the Drywell are retorqued at one time. Should
indications of problems be identified in the half
being worked, and evaluation of the root cause is
performed and the need for retorquing additional
valves done.
Once all valves have been retorqued at the 6-year
frequency, results should be evaluated to allow
for a frequency increase, it is believed an
increase to at least 8 years could be achieved at
that time. It is believed that retorquing after
repack is a progressive frequency and need not
remain fixed, but should increase after each
successful interval.
YR
B-4
Valves found undertorqued (record number of flats to tighten).

Valves with minimal take-up remaining (record take-up).
Valves which visually show signs of past leaking.
If any significant problems are found, contact Argo/Engineering immediately to
evaluate potential generic implications.

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
New RTs
ID(s)
No
Components
attached
Item
M1
Activity
Number
V0505-05
V0505-55
Description
Retorque Valve
Packing for
Manual Valves
IDd by
Argo/Engineering
Scope
Retorque packing of manual valves that are identified by Argo or Engineer based on
their review of:
Past history.
Failure investigators.
Industry events/experience.
Walkdown results.
New RTs
No
Components
attached
M2
V0505-06 A Cell
V0505-07 B Cell
V0505-08 C Cell
V0505-56 A Cell
V0505-57 B Cell
V0505-58 C Cell
Retorque Valve
Packing for
Manual Valves in
Heater Cell
Retorque packing of all manual valves in the Feedwater Heater Cell identified for this
RTPM.
Basic Information
This activity provides for an overall routine review
of valve packing performance, and investigation
of any areas that may seem weak. Based on the
age of our packing >1214 years, which is
significantly older then any other industry
program, we must remain vigilant for the first
signs of degradation or excessive wear. If no
unique issues develop, this RT may be
waived/closed based on the other RT that should
cover all known areas.
YR

approach to maintaining valves in moderately
Severe environments outside of containment.
Valves have been retorqued at the 6-year
frequency for several cycles, results were
evaluated, and a frequency increase, to at least 8
years is reasonable and was increased via PMR.
It is believed that retorquing after repack is a
progressive frequency and need not remain fixed,
but should increase after each successful interval.
YR
B-5

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
ID(s)
Manual Valves
in Main Steam
Drip Legs
Bypass Drip
Legs Steam
Tunnel
No
Components
attached
New RTs
No
Components
attached
Item
M3
M4
Activity
Number
V0505-01
V0505-51
V0505-10
V0505-60
Description
Scope
Basic Information
Retorque Valve
Packing for
Manual Valves in
Main Steam Drip
Legs Bypass Drip
Legs Steam
Tunnel
Retorque packing of manual valves in the Main Steam Bypass Drip legs identified for
this RTPM.

severe environments outside of containment.
frequency for several cycles, results were
evaluated and a frequency increase, to at least 4
years is reasonable and was increased via PMR.
It is believed that retorquing after repack is a
Due to the severe environment of Main Steam
and its pressure pulsations, this has been a
problem area, but with the latest yarway packing
configurations and policy to rework any packing
leaks, all current issues appeared addressed, and
further supported the frequency extension to 4
years.
YR
Retorque Valve
Packing for
Manual Valves in
Moisture
Separator Drain
Tank
Retorque packing of all manual valves in the Moisture Sep Drain Tank identified for
this RTPM.

Severe environments outside of containment.
frequency, but were not clearly part of past RTs.
Results from upcoming cycles should be
evaluated and frequency adjusted accordingly. It
is believed that retorquing after repack is a
Initial frequency established at 6 years due to the
moderate environment seen at this location until
all areas have been retorqued at least once.
YR


B-6

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
New RTs
New RTs
ID(s)
No
Components
attached
No
Components
attached
Item
M6
M7
Activity
Number
V0505-12
NEW
V0505-62
NEW
V0505-14
V0505-64
Description
HPCI Manual
Valve Retorques
RCIC Manual
Retorques
Scope
Retorque packing of manual valves along the HPCI steam line outside containment.
Retorque packing of all manual valves along the RCIC steam line outside
containment.
Basic Information
This type of activity has proven to be the least
cost approach to maintaining critical manual
valves in Severe environments.
Valves have been retorqued in the past under
PCWOs, but an RT was never created. This new
RT is established with an initial frequency of 6
years, to ensure we proper monitor packing
performance in this area. HPCI is a critical safety
system; out of service time must be minimized
and temperature is monitored in areas and will
cause isolations. Due to the severe environment
of HPCI Main Steam and its pressure pulsations,
this is a prudent RT. It is believed that retorquing
after repack is a progressive frequency and need
not remain fixed, but should increase after each
successive interval. After review during the next
implementation, extension of frequency should be
reviewed; actual results should dictate frequency
change.
YR
This type of activity has proven to be the least

cost approach to maintaining critical manual
valves in severe environments.
Valves have been retorqued in the past under
PCWOs, but an RT was never created. This new
RT is established with an initial frequency of 6
years, to ensure we proper monitor packing
performance in this area. RCIC is a critical safety
system; out of service time must be minimized
and temperature is monitored in areas and will
cause isolations. Due to the severe environment
of RCIC Main Steam and its pressure pulsations,
this is a prudent RT. It is believed that retorquing
after repack is a progressive frequency and need
not remain fixed, but should increase after each
successful interval. After review during the next
implementation, extension of frequency should be
reviewed; actual results should dictate frequency
change.
YR
B-7

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
RWCU
Manual
Retorques
ID(s)
No
Components
Attached
Item
MS
Activity
Number
V0505-02
V0505-52
Description
Reactor Water
Cleanup Manual
Valve Retorque
Scope
Basic Information
Retorque packing of a sampling of manual valves on high-temperature RWCU

lines outside containment.
This type of activity has proven to be the least cost

approach to maintaining critical manual valves in severe
environments.
Valves have been retorqued in the past under PCWOs.
This RT was established with an initial frequency of 8
years to ensure we properly monitor packing
performances in this area. RWCU is a critical safety
system; out of service time must be minimized and
temperature is monitored in areas and will cause
isolations. Due to the moderate environment and ALARA
concerns, it is believed that retorquing after repack is a
progressive frequency and need not remained fixed, but
should increase after each successful interval. After
review during the next implementation, extension of
frequency should be reviewed; actual results should
dictate frequency change.
YR
This activity has proven to be the least cost approach to

maintaining critical MOVs in severe environments (Main
Steam). These MOVs are retorqued every 8 years. With
the exception of V0501-01-07/51-57, these RTs were
created in 2001. Prior to this time, valves were retorqued
either as part of special PCWOs written to cover an
area, or similar valves when one problem occurred or
when a leak was noted. Based on the few leaks that
have been experienced to date, 8 years was established
as the initial frequency to be adjusted based on
experience. It is believed that retorquing after repack is a
progressive frequency and need not remain fixed, but
should increase after each successful interval.
YR
This activity has proven to be the least cost approach to

maintaining critical MOVs in severe environments (Main
Steam). These MOVs are retorqued every 10 years.
With the exception of V0501-01-06/56, these RTs were
created in 2001. Prior to this time, valves were retorqued
either as part of special PCWOs written to cover an
area, or similar valves when one problem occurred or
when a leak was noted. Based on the few leaks that
have been experienced to date, 10 years was
established as the initial frequency to be adjusted based
on experience. It is believed that retorquing after repack
is a progressive frequency and need not remain fixed,
10
YR

After sample is completed, contact Argo/Engineering to evaluate results to
decide if additional work is necessary.
Argo or Engineering to ID scope for this RT based on past experience.
S1
BOP MOV
Main Steam
S2
BOP MOV
Low-Pressure
Steam
See List
Attached to
PMT for RT
Components
See List
Attached to
PMT for RT
Components
S1
S2
See List
Attached to
PMT for RT
Numbers
See List
Attached to
PMT for RT
Numbers
BOP MOV Valve

Packing Retorque
(Main Steam)
BOP MOV Valve

Packing Retorque
(Low-Pressure
Steam)
Retorque the packing per MT-GM-011 on the identified valve(s):
Prior to retorquing the gland stud nut, it should be verified to turn free by
breaking with a box wrench loosen/tighten the nut turn in each
direction, returning the nut to its original position.
Lubricate as necessary per MT-GM-011.
Torque the gland follower nuts to the identified torque value on the valve
data sheet.
Inspect for degraded conditions, i.e., loose nuts, signs of leakage (new).

Prior to retorquing the gland stud nut, it should be verified to turn free by
breaking with a box wrench loosen/tighten the nut turn in each
direction, returning the nut to its original position.
Torque the gland follower nuts to the identified torque value on the valve
data sheet.
B-8

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
ID(s)
S5 BOP MOV
Low-Pressure
Steam
See List
Attached to
PMT for
Components
Item
S5
Activity
Number
No RTs
Description
BOP MOV Valve
Packing (Very
Low-Pressure
Steam)
Scope
Prior to retorquing the gland stud nut, it should be verified to turn free by breaking
with a box wrench loosen/tighten the nut turn in each direction, returning the nut
to its original position.
Torque the gland follower nuts to the identified torque value on the valve data
sheet.
Basic Information
Based on the extreme low pressure of the steam
at these valves, a benefit to a periodic retorque
could not be found for these valves. Adequate
monitoring of these valves is provided by the
extensive and detailed walkdowns performed to
the entire plant.
If repetitive problems begin to occur, this group of
valves should be reevaluated.
Never
Because there is only hot water not steam at

these valves, a benefit to a periodic retorque
could not be found for these valves. Adequate
monitoring of these valves is provided by the
extensive and detailed walkdowns performed to
the entire plant.
If repetitive problems begin to occur, this group of
valves should be reevaluated.
Never
To balance the impact of unidentified leaks

occurring, which would not be caught soon
enough to prevent a repack, ALARA concerns,
and system leakage limits, these PMs were
established to provide reasonable assurance that
packing leaks will not occur in RWCU system.
Due to ALARA, the results of this PM should be
closely reviewed to determine if PM frequency
extension is advisable, noting that it is believed
that retorquing after repack is a progressive
frequency and need not remain fixed, but should
increase after each successful interval.
Some of these valves were originally covered by
PMs at a 6-yr frequency.
8 YR
NO RTS ARE PLANNED FOR THIS GROUP OF VALVES AT THIS TIME.

PMT missed the fact that a few MOVs had historically been covered by RTs,
based on limited review these MOVs were not deleted from these RTs at this
time (i.e., HV12713A/B/C, 14, 17).
S6 BOP MOV
(Hot Water)
Retorque
See List
Attached to
PMT for
Components
S6
No RTs
BOP MOV Valve

Packing Retorque
(Hot Water)
sheet.
NO RTS ARE PLANNED FOR THIS GROUP OF VALVES AT THIS TIME.

S6 BOP MOV
(NON VOTES)
(Hot Water RX
Cleanup)
Retorque
See List
Attached to
PMT for
Components
S6R
V0506-01
V0506-56
V0501-06 in
Drywell
V0501-56 in
Drywell
V0506-01 Outside
V0506-51 Outside
MOV (NonVOTES)
Retorque Packing
(Hot Water RX
Water Cleanup)
Retorque the packing per MT-GM-011 on the identified valve(s).
sheet.
Contact System Engineering for Special Evaluation of HV244F101, which is

deactivated and has known stem damage to determine if any actions should be
taken.
B-9

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
ID(s)
S9 BOP MOV
(NON VOTES)
(Special App.
Drywell,
Wingslab)
Retorque
See List
Attached to
PMT for
Components
V1 VOTES
Valves with
Critical History
See List
Attached to
PMT for
Components
Item
S9
V1
Activity
Number
Description
Scope
V0501-15 deleted
V0501-16
V0501-17
V0501-18
V0501-65 deleted
V0501-66
V0501-67
V0501-68
MOV (NonVOTES)
Retorque Packing
(Special
application
Drywell and
WingSlab)
DELETED
HV1/241F032A/B
since PM
disassembles
every 4 yrs
See List Attached

to PMT for
Components
VOTES packing
Retorque
VOTES/LLRT Valve contact Engineering to coordinate work.

Due to the past packing history and critical service of this valve, this RT
is used to ensure that the packing is properly maintained. Engineering
may waive the requirement for VOTES as PMT, and the impact on
LLRT must also be assessed. Based on these reviews the following
scope.
ALL AOV
Valves
See
Program for
Components
X1
Retorque Valve
Packing for ALL
CRITICAL AOVs
Prior to retorquing the gland stud nut, it should be verified to turn

free by breaking with a box wrench loosen/tighten the nut turn in
each direction, returning the nut to its original position.
Torque the gland follower nuts to the identified torque value on
the valve data sheet.
Inspect for degraded conditions, i.e., loose nuts, signs of leakage
(new).
Prior to retorquing the gland stud nut, it should be verified to turn

free by breaking with a box wrench loosen/tighten the nut turn in
each direction, returning the nut to its original position.
Torque the gland follower nuts to the identified torque value on

the valve data sheet.
Inspect for degraded conditions, i.e., loose nuts, signs of leakage

(new).
Valve packing performance monitoring is directly integrated into all AOV

PMs.
NOT FOR UPLOAD.
Refer to AOV PMT and BID for details.
B-10
Basic Information
Because these valves are not VOTES-tested but are located in
critical areas that are not easily accessible (Drywell/WingSlab)
and have Tech Spec Limits for which packing leaks could
cause a Plant Shutdown, these activities were created.
Drywell >3 gpm leak Plant Shutdown
Wingslab High-temperature MSIV Isolation
These valves have never been retorqued on a regular
frequency, but because of the impact discussed above, an
initial frequency of 8 years was selected.
Due to ALARA, the results of this PM should be closely
reviewed to determine if PM frequency extension is advisable,
noting that it is believed that retorquing after repack is a
progressive frequency and need not remain fixed, but should
8
yr
Because these valves are VOTES-tested and are located in

critical areas that are not easily accessible (Drywell/WingSlab)
and have Tech Spec Limits for which packing leaks could
cause a Plant Shutdown and these valves have poor history,
RTs have existed.
These valves have been retorqued on a regular frequency, with
a frequency of 4 to 6 yrs depending on history of fluids media.
Due to ALARA, the results of this PM should be closely
reviewed to determine if PM frequency extension is advisable,
noting that it is believed that retorquing after repack is a
progressive frequency and need not remain fixed, but should
4
yr
The scope of AOV PMT covers all related valve packing issues.
Originally the packing program drove the AOV diagnostic
testing, but as the AOV program has matured, the testing has
expanded to address additional issues. However, packing
performance monitoring remains a critical task on all AOV RTs.
As-found packing drag is monitored, and packing loads are
adjusted to ensure adequate load is provided via as-left
measurement.
N/
A
6yr

Table B-1 (cont.)
Reference Number:
Valve Packing
Packing-1
Criticality
Duty Cycle
Service Condition
Group
ID(s)
VOTES MOVs
See
Program for
Components
Item
X2
Activity
Number
Description
MOV Retorque
During VOTES
Testing
Scope
Valve packing performance monitoring is directly integrated into all VOTES MOV
PMs.
NOT FOR UPLOAD.
Refer to MOV PMT and BID for details.
MSIVs
HV141F022
A-D
HV141F028
A-D
X3
MSIV Retorques
MSIV PM routine includes step that addresses inspection and retorquing of MSIV
valve packing.
Basic Information
The scope of VOTES MOV PMT covers all
related valve packing issues. PPL pioneered the
use of VOTES data to monitor and maintain valve
packing load. Packing performance monitoring
remains a critical task on all VOTES MOV RTs.
As-found packing drag is monitored, and
packing loads are adjusted to ensure adequate
load is provided via as-left measurement.
N/A
Refer to MSIV PMT, for details of these activities.
N/A
NOT FOR UPLOAD.

Refer to MSIV PMT and BID for details.
HV241F022
A-D
HV241F028
A-D
B-11
Target:
Nuclear Power
Technology for Equipment
Assessment & Maintenance (TEAM)
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Valve Packing Performance Improvement

Sealing Technology & Plant Leakage Reduction Series

Valve Packing Performance

Final Report, March 2002

EPRI Project Manager

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

Valve Packing Performance Improvement is the seventh in a series of training modules

Leakage management programs

Assembling bolted joints with spiral-wound gaskets

Preload requirements for bolted joints with spiral-wound gaskets

Lube oil system leakage mitigation

Leakage reduction from threaded joints

Leakage reduction from bolted joints with sheet gaskets

To provide maintenance personnel, work planners, engineers, QC personnel, and plant

To develop cost-effective, plant-specific programs to reduce leakage from these joints

Work planners should be able to provide better information in work packages.

EPRI Licensed Material

Leakage management programs

Assembling bolted joints with spiral-wound gaskets

Preload requirements for bolted joints with spiral-wound gaskets

Lube oil system leakage mitigation

Leakage reduction from threaded joints

Leakage reduction from bolted joints with sheet gaskets

Identification of the types of valve packing available

Identification of the causes of valve packing leakage

Development of a program to reduce valve packing leakage

Preparation of training materials, including a Valve Packing Performance Demonstration

EPRI Licensed Material

Target Audience ..........................................................................................................1-1

Relationship to Existing Plant Procedures ...................................................................1-2

Valve Packing Performance Demonstration Unit.........................................................1-2

2 REVIEW OF VALVE PACKING CONCEPTS ........................................................................2-1

Alternative Methods for Sealing Valve Stems..............................................................2-1

Valve Packing Concepts ..............................................................................................2-2

3 VALVE PACKING LEAKAGE EXPERIENCE........................................................................3-1

Boric Acid Corrosion Guidebook..................................................................................3-1

Review of Plant Maintenance Records ........................................................................3-2

4 VALVE PACKING CONFIGURATIONS AND PRODUCTS...................................................4-1

Valve Packing Technology Evolution...........................................................................4-1

Braided Asbestos Packing (Figure 4-1.a) ...........................................................4-3

Braided Non-Asbestos Packing (Figure 4-1.b)....................................................4-3

Die-Formed Flexible Graphite Packing With Braid End Rings

Engineered Die-Formed Flexible Graphite Packing System (Figure 4-1.d) ........4-5

Components in Die-Formed Flexible Graphite Packing System..................................4-5

Die-Formed Flexible Graphite Packing Rings .....................................................4-6

EPRI Licensed Material

Packing Washers ..............................................................................................4-12

Junk Rings ........................................................................................................4-13

Gland Bolting and Hardened Steel Washers ....................................................4-13

Live Loading ..................................................................................................4-14

Components in Braid Ring Packing System ..............................................................4-15

Braided Asbestos ..............................................................................................4-15

Braided Graphite Fiber Yarn .............................................................................4-16

Braided Carbon Fiber Yarn ...............................................................................4-16

Braided Flexible Graphite Tape ........................................................................4-16

5 CAUSES OF VALVE PACKING LEAKS ...............................................................................5-1

Low Gland Stress ........................................................................................................5-1

Packing Consolidation .................................................................................................5-2

Dimensions and Clearances ........................................................................................5-5

Stem and Stuffing Box Surface Finish .........................................................................5-6

Stem and Stuffing Box Corrosion.................................................................................5-7

Stem Misalignment ......................................................................................................5-8

Stem Thermal Taper ..................................................................................................5-10