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What's New in GASLOCK Packing Welcome to trie world of comoression packing1 GASLOCK is interested in having you - - our valued customer - - unoerstano the types of pacing avanaoie to you ang now to oest use them Our "Wear's New in Gariock Packing" program nas Deen cesigneo to provide the answers you li need to solve a wide variety of eauipment maintenance pro blems. You II find the booklet that accompanies the audio-visual presentation a handy tool to refresh your memory aoout the use of compression packing. Please refer to it as frequently as necessary to solve your packing prooiems. This cookiet and the "GAPLQCX maustnai Prooucts Catalog" will provide you with all the information you need for selecting the oest packing suited to your reouirements. Premature packing failures snouic oe a thing of the past. Realizing, however, that not every unique prooiem can be covered m our packing program, piease feel free to call on us with your particular application Contact your GARLOCK field service representative or me inside Sales Department of our Soous facility. j ncr ?s ?cxma .-'ctnr. Welcome 'o me GARLCCK Packing Clime Your company re alizes me need lor mis sort of educational meeting on comcression packing ano we are very pleased to nave tms op portunity to snare our nnowiecge ano experience witn you GABLCCK mam piant ana general offices are 'ocated m Palmyra. New York SLIOC ' ana our Compression Packing facility has moved to newer and more efficient auarters m Sodus. New York We want you to xnow wnere we re located and wnere our products are procuced. These plants sit on more than 100 acres and rep resent an investment of several million dollars m facilities to produce packings, gaskets ana seals GARiOCK also has other piants woncwce to produce ana aismoute their com plete ime of products. GAPLOCK has Deen the leaaer in me packing industry for nearly a century The products have cnangea dramatically smee O J Gartock cut his first set of packings from ruooer nose m 1887 ana GAPlOCK is still the 'rpntrunner in researen anc aeveiopment of new products for an types of industries. SLIDE >3 in this discussion we win oe talking aBout packings as dynamic sealing materials Dynamic packings seal moving parts. There are three mnes of motion mat usually must oe sealed: reciorocating motion as m reciprocating pumps rotary motion as in centrifugal pumps' ana neiicai motion as is founa m valves SLIOC ! SLIOC o SLIDE -a Dynamic packings are used to retain an types of fluids unaer different amounts of pressure, including vacuum, at varying temperatures To seat mis great variety of fiuics. hundreds of materials and luDncants have Deen developed, although as you know a nancful of mem will handle me vast maionty of ap plications Let s now iook at some of the more popular materais ana constructions of compression packings 127 *o ^!r PAPERPAK SOOi GRAPH-t-OCK i ^ __^TERAa t SLIPS M SLIPS slips *r slips 2 SLIDE *5 Metai is usually found in compression :ac*'r:s i. tnougn some metal >s useo m araiceo ana snreooec `a -- s You ii fmo metais usea as end, rings as wen as pressure or thermal Darners in rugn pressure or nign temperature service The commonly useo metais m metallic packing s_c~ as ou see here are ieaa. copper and aluminum Metal packings are commonly louna in a twistec core con struction Sometimes you may see a folded crumpied oDraided metai packing Some metais nave less `ncron aca ns: moving surfaces man fibers The crumpieo anc `oioec t.ces are luDricateo oetween the layers to form reservoirs 'or _cncanon Metallic packings are generally used at illOE t6 higher speeds, and also as end or Dull rings wnn otr packing to prevent extrusion. uLICE -7 AsOestos. a mineral fiber is widely used because of :s strength, temperature resistance, ano versatility '.vn.te as bestos. because of its snort fiber length must De Tterrueo with rayon fibers to facilitate braiding The presence of t-ese rayon fibers nmits me use of white asoustos packings to "a-anng aikaimes. neutral or weak acid solutions 3iue ascestos fibers are longer and don t reauire tre aic of rayon so caches from this family can oe useo on eouipment -anoiing strong mineral acios SLIDE *9 are also usea to manufacture compression packings They nave a temperature limitation of 220 F ana are primarily coia water ana coia oil packings. vegetaoie fioer packings are ex cellent tor tnese applications Because me fibers actually get stronger as mey get wetter SLIOE *10 Synmetic fiters came on me marxet a few years ago ana nave naa Quite an impact m tne packing mcustry The oest known of tnese liters, of course, is TEFLON' TEFLON nas a low co efficient of friction, can handle fluids m a pH range of i -- 14. ana temperatures uo to 500 F There is a new synthetic fiBer on the market known as KEVLAR' This new product contains no asoestos is extremely duraOie. and can handle temper atures uo to 550*F and a pH range of 4 through 10. SLIDE *11 Througn updated technology ana GARLOCK engineering come tne most exciting, cost-saving packings maae from caroon and graohitic fiOers. Even tnougn these products cost more on a oound oasis, they actually save industry thousands of maintenance dollars Because of fewer repacks, fewer ad justments. less product loss, and more feet per pound foryour packing collar. Caroon/grapnite products can Be used every where in every type of industry. They are chemically inert, han dle oh ranges from i -- 14. temperatures to 650*F (1200*Fm steami. they nave great thermal conductivity characteristics, ana no prooiems with thermal expansion. These packings are truly the "problem solvers" for today s industries which use exotic chemicals, higher temperatures, and faster shaft speeds. SLIDE *12 Now let s look at how these materials are constructed ana act ually manufactured into packing Let'smvestigatetneaifferent shapes of packings and wnat advantages tnese different con structions offer you m actual performance. Twisted packing is the first construction we will discuss. Twisted does not have the strength of Braided packing; there fore. it is mainly suitaoie for valve stems. You ll find it useful primarily Because it can Be untwisted to create smaller sizes mat you may need. There are three types of popular oraid Simple sauare Braid is produced By one trip through the oraiamg macrnne. The Braids are not firmly locked in sauare oraia construction The advantage is mat ns strands can adiust to uneven rod motion on older eauipment. Sraid-over-braid is a round packing, made up of a senes of Braided tubes, one braided over me other It's a dense packing ana is used for higher pressure |OBs on rods or valve stems or wherever there is relatively slow motion it resists extrusion, which makes n particularly useful m reciprocating service it can aiso oe used as a gasketing ma:eriai on oven doors, cruciDies or any tongue-ano-groove application SUO( It SUOt '0 suoe " TWISTED suoe >i2 BRAtD-OVBHMI^^i 3 SUOf u SLIDE *13 LATTICE BRAIO* combines fIe*>D <ty and f'rmness Each braided strand masses diagonally tnrougn me oody of me packing forming a completely unified structure it >s naturally snaped sauare m cross section and every strand contnoutes to its strengtn The important feature is mat wear does not loosen the stranos Whereas anotner packing wouic oe ser-cus ., damaged. LATTICE BRAID maintains its unified structure suoc U SLIDE *14 To the braided product, impregnants and lubricants are added to fill voids and provide additional lubrication Thougn impregnants and lubricants do not help construct the form or shape of a piece of packing, they are vital to backing service ana actually constitute a fair percentage of most kmcs of oraiceo packing. Impregnants include taiiow iaro oil fish oil soap, castor oil. paraffin, lubricating oil. silicones. tefions. graptite mica, and many others, depending on service requirements One of the mam reasons for good packing performance lies in matcnmg the impregnant or luoncant to the panicutar appli cation SUOC >13 SLIOI SIC^S THROTTLING SLIDE *15 We now have our finished product ready to oe installed Com pression or jam-type packings are "soft-packings' that are installed m me stuffing oox and adjusted from time to time oy taking up a gland The packing constructions mat are included among compression types are twisted, braided, laminated cloth, shreoded. and tne metal foils. They are found, as you know, on rotary, helical, and reciprocating applications Now that we ve touened on the high spots of packing mater ials. how they are out together, and the ways mev are used m dynamic sealing, we come to a very important stage -- meir in stallation and proper maintenance SLIDE *18 Your joo of working with packings is mceeo an art. because yours is the tough and elusive prooiem ot throttling leakage between a moving and a stationary pan Racking does not stop leaks. Packing controls leakage by throttling. The key word >s throttling, which means there must be some leakage 4 SLIDE 17 Packings tnemseives must not run ary K tney ao. n creates neat, wear, ana aestruction ot the pacing, along witn scoring ot the shaft. You can literally make packings worn very well or fail completely SHOE alS Before we get to the actual installation, let s aiscuss tnetneory of how compression packings work With all types of materials and all kinas of packing, the key to successful maintenance is keeping leakage to a point where it merely luDricates ana cools the packing, without resulting m a serious loss of the fluid being sealed. An average leakage rate is 10 to 12 drops per minute for conventional type packings, ana considerably less tor the carbon and graphite types. Pack ing that is saturated witn a lubricant acts as a safety valve m tne event that packing is over-tightened and fluid flow is actually cut off SLIDE 19 in typical packing installations, you would snug up the packing py tightening the gland. In operation, tne fluid flows tnrougn the tiny clearance between tne moving parts and the packing and acts as the lubricant, as shown in Sketcn A Now see what happens if you over-tighten the gland The leakage will be reduced or eliminated, but this in turn will cause tne packing to run dry and create heat from friction on the snaft. This neat will melt the impregnant in the packing as in Sketch 5. and creates a flow that will supply the vital lub ricant necessary to keep the packing from burning up. and the snaft or rod from scoring. However, the impregnant that has meiteo out of the packing has reduced the packing's volume. Soon, an has cooled down and leakage Stans again, as you'll note in C. So again we adiust. If this cycle is repeated several times, tightening the gland iust enough to stop fluid leakage, you will eventually compress the packing to tne point where no impregnant or internal lubricant remains. At this point--Sketcn 0--there s a cloud of smoke, and burned packing and scored shaft. You can see the moral of this story: Never tighten the gland to eliminate all fluid leakage from a rotating snaft or reciprocating rod. Packings lubricated with grease and oils have this built-m safety factor but must be repacked more often because ot the volume loss. SLIDE *20 The newer carbon and graphitic packings reauire closer atten tion during installation and break-m period, but after that they are maintenance and trouble free because mere are no lubri cants or impregnants to leak out--the moral to mis story tower maintenance costs. rr SUP* 'T tuoc no S SLID* <31 SlIOC <32 6 SLIDE *21 When you ao nave a packing faiiure--wnatever mecause--you have a nasty 100 on your hands Packing a oumo may sound like a simple procedure, however, nearly 60% of an average plant's packing prodiems come from improper installation or maintenance, rather than tne packing itself Let's go througn a soft packing installation now step ov steo and get a feel for the important ideas to keep m mmp SLIDE *22 First, remove all the old packing Modern stuffing boxes are designed to hold lust enough packing to do the job. it is. there fore. important that eacn ring be replaced with new packing Merely adding a ring will only result in quicker shaft and sleeve wear. The bottom rings m a packing installation seal against clearance space at tne bottom of the stuffing box They ne'p keep impurities, as found in slurry service, away from me work-horse rings located next to the packing gtano When these impurities get under the packing set. they normally cause early packing failure and severe snatt damage, m fieia packing rep'acement. conditions are most often found to oe uncomfortable. Frequent excuses include--it is too not or too cold, you can be cramped for space, and you may not feei mat you have enougn time to do a proper installation /oo Remember, a good repack the first time with a quality packing will eliminate the cnore of having to do it again ngnt away SLIDE *23 When removing the old packing, remember to aim your packing nook and tools away from the snaft to avoid damage A mck or gouge m the shaft will rapidly tear up me new packing SLIDE *24 You are now at a very important phase m packing replacement --inspection The equipment must be m good condition if you are to expect long packing life Examine me snaft for excess ive wear Use a mirror and flashlight to check the snaft for cuts and gouges Many times the causes of packing failures are not readily apparent. However, careful examination of the used packing will often indicate the factors causing this faiTure The following slides snow some examples of how certain clues can pinpoint the reason for the failure: SHOE *25 1 If one or more rings are missing from tne set look for ex cessive snaft clearance allowing extrusion of rings into me system As a result of mis condition packing may get traooea m omer eouioment or contaminate me fluiO Oemg nanoieo 2. if packings rena to sneet-out or extrude Between rod or snaft and giano follower, iook for too great a clearance Be tween roo or snaft ano gland follower use Of anti-extrusion rmg mav oe necessary if tne pressure is nign or if clearances cannot Be reduced SLIDE *26 3. If packing radial tmckness appears other than nominal m one or more places, look for an uncersize shaft. Badly worn Bearings, causing shaft Whip or rod or plunger wooflle SLIDE *27 4 if packing -aoiai thickness directly Beneath the rod, snaft or plunger is excessively reduced or early leakage occurs at too of rod or shaft iook 'or misalignment of centerlines of snaft or rod and stuffing box pore 5. If outsice diameter of oacking is worn look for loose ring or rings rotating witnm snaft due to insufficient gland load SLIDE *28 6. If one or more rings has "bulges " m me faces look for ad jacent rings cut too snort, causing pacing under pressure to oe forced mto tne spaces at the joints. 7. If Bottom rings are m fair condition yet rings next to gland followers are prematurely deformed, look for improperly in stalled packings anc use of excessive giano pressure When you are sure vour equipment is -n good conction ycu are reacv to nstail rew pacing SUO* >15 > i- Sl'OI suofJ0 suoe hi 4U0(M 8 SLIDE -29 Using jne correct size anc type oacmng >s very moortart A packing survey will list an eauipment using pacxmgs anc me Drooer Size to use It will also snow now many rings Ol packing go on eacn siae ot tne lantern ring it you don t now nave a packing survey, GARlGCK will De naooy '0 conduct one ano assemoie a reoorr for you at no cost SLIDE -30 Without a packing survey you will need to measure me snatt and stuffing oox to ootain tne proper size Subtract me snatt diameter trom tne stuffing oox diameter ano divide cy two This is your pacxing size SLIDE Ol You will nave to cut rings to the prooer size A pacxmg cutter such as you see nere win give you a ring mat will oe a precise fit. which is very important to controlling leakage. SLIDE 32 Simply lay tne correct packing on me scale ana cut The result will be a perfectly cut ring 3LI0E =33 it you son t nave a oacxmg cutter wtao tne packing arounc a red or steeve tne same size as tne snaft. tnen marK ana cut SLIDE =34 Avoid cutting tne packing lying flat. You will prooably wind up witn a vee snaceo gao as snown nere. Cutting flat is acceptable if you nave already measured a good fitting ring ana can use it as a guide for cutting tne rest of tne set. 4X- ?*/i 1C10I >33 UIOI <M SLIDE =35 These packing rings were taken out of a set wnicn we found wnen caned to examine a oremature oackmg failure Notice tne ouige on tne ring second from tne left. The ring next to it was cut approximately one inch too snort. The packing leaked tremendously on installation ana tne mechanic really tight ened tne gianc to cut down on leakage as you can see by tne first two rings on the left which are ournea ana fused togetner This also snows you that in a packing set the rings next to the giana apply approximately 70% of the mechanical pressure to the snaft anc are the first to burn The ring on the right is from tne bottom of the set ana is practically new To make a long story snort, no amount of tightening will mane an improperly cut set of packing worn--it will only lead to snaft and pump ) damage. SLIDE =36 Now that we nave tne proper size pacxmg cut to the proper ring sue. we are ready for mstanation-or are we1 Packing often comes from tne factory shgntiy oversized m order to provide a snug fit if the pacxmg will not go mto the box. do not hammer it Mat this creaxs down me fipers and rums the packing structure suot os 9 SLIPS 07 1U0I Oi suot m SLIDE *37 Carry a snort lengtn of pipe in your tool oox ano ron :ne oacxing flat--it is quicker ana Detter tnan Hammering Notice we are using a orotective oiece of oaoer uncer :ne packing to Keep me oackmg clean so mat aoraswes ao not get on me sacking ana damage tne snaft or sleeve SLIOE *38 Now tnat tne packing fits precisely install me first ring into me stuffing pox it neios to stick an ena siigntiy mto me dox ana twist gently to insert tneouieredgeofmeoackmgrmgintome stuffing oox SLIDE MO Seat eacn ring individually by inserting tne packing giana into the stuffing oox. 10 SLIDE *41 Alter seating eacn ring, rotate tne snatt 360 Dy nanc This heios to seat tne oackmg ana to dismoute luortcant wmcn is critical on initial start-up SLIDE =42 impregnated packings cannot contain enough luDricant to give satisfactory service unoer extremely nign temperatures or where conaitions create nign (rictionai neat External lubri cation must De supplied External tuoncation is aiso reauirea when you re sealing liuios or gases mat are not satisfactory tuoricants. or wnen an acid or otner toxic suostance is invoivea ana cannot leak mto the atmosphere But -- something must leak or you don t nave a good packing .nstaifation SLIDE *43 in sucn cases, you'll be involved with eau'oment mat provides a lantern ring near the middle of me stuffing oo* and external lubrication is supplied here. Anything from a simple greasecup fitting to a separate pumping system may be used Con tinuous luorication is better man intermittent, so if you nave eauioment with grease-cup fitted lantern rings it is important to lubricate mem frequently SHOE *44 The lantern ring is often spin, as you see ''ere to maxe install ation easier SllOC SLID! Ml ii snot < SUDC SLiot r SLIOE *45 When inserting tne lantern rmg ma*e aosoiutew sure :"a; t >s unger the lubrication opening Chec vour survev tor :re proper numoer of rings to install oenina the lantern ring it tne soace is targe enough you can use your nano to *ee> me - cation ooenmg m tne stuffing oo 3e sure to iuo* enc^c- clearance to move the ring cacx into me stuffing o0, t 3tr o< an inch' You are now reaoy to msert tne remaining rings mto the Stuffing oox Remember to seat eacn ring m.OivCuaiiv SLIOE *46 The packing will be neid in the stuffing oox ov a cacxmg giano as is seen here SLIOE *48 The giano fits mto the stuffing oox as you see nere P-essute can oe aaiusteo on tne packing oy tigntenmg tne nuts on ;-e oolts which pass through me noies you see m me giano 12 5LIDE ;-9 On a c'cce' "stanation tne giana wm s11 souareiy on me packing v;of set wm tnen oe seatea prooe'iv as snown SLICE -SO An imoroceriv seated set mvites trouoie As you can see tne packing win 'ean ana me giana will oecome cocxea The packing is extruding arouna tne mtea eage of tne giana This is a common occurence ana can ieaa to snaft carnage Oearmg failure ans many otner expensive orooiems SLIDE -51 Witn our packing installation comoiete we are now reaav tor startup T-e i's:`ew seconos ot operation are critical Tn.s's tne time mat me fiuia cemg'pumoea nas not completely oenetratec tne pacing m oraer to proviae sufficient luoncanon it is at mis pent wnen you are most imeiy to burn tne packing Witn conventional type packings snug tne giana up witn a wrench ana men pack tne nuts off until they are finger ngnt. Wnen worxmg witn teflon, caroon. ang graonite products only snug tne giana uo finger tight. Leave tne wrencn in your pocket. Turn me snaft by hand to mane sure n isn't omamg Turn on ail vaives ana make sure fiusnmg connections are flowing aaeauateiv Hit tne start-up outton ana run the pump for aoout a or 5 seconas only Then leave tne pump off fora few seconcs to allow tne fluid to penetrate tne set. Restart tne eouipment ano allow it to leak until the packing seats itseit wmcn is usually when stuffing box temperatures oegm to level off. Then aaiust the giana nuts one fiat at a time for conven tional packings ana one quarter of a flat for caroon ana graonite packings, until you reacn tne aesirea leakage rate it 9 may take a cay or two before you can maxe tne fmai aciustments. Put longer packing life maxes it wortn tne effort SLIDE *52 The wrencn 'S tne greatest enemy of most compression packings. Cvertigntenmg is tne greatest cause of premature packing failure ana equipment damage Try to rememoer tms simple tip -- aaiust oacxing -ao not tignten it Don't try to solve a leakage problem by tigntenmg aown on tne packing Peoiace tne oacxmg or repair me equipment anc you can save thousands of collars anuaiiv m unscnecuiea down time anc equipment carnage suoe suoc 13 SLlOl iJ slip* >u SLIOE 'S3 Try 10 keep plenty of :ne riqnt size anc type pacmng on nano and avoid suBstitutmg a pacxing wruc-n may not oe rignt tor me |0D SLIOE S4 Store your packing m a clean area to avoid oicmng up dirt ana aBrasives that are damaging to packing ana equipment SLIDE *55 We nave not covered one new type ol packing material tnat re quires a siigntiy different metnod of pacmng it's caned pure grapnitic tape. This type of packing is rapidly coming into use Because of ns cnemical and neat resistance wnicn gives n very long life especially m valve stems. There are no Binders or fillers to wasn out and cause volume loss so inis means mere are fewer adjustments, fewer repacks, fewer aggravations, ana lower maintenance costs. SLIDE 56 First, loosen the packing nuts, remove the oid packing, ana clean me stuffing box. SLIDE >57 Wrap sufficient race arounc me stem rp mi me stuffing oo* am meter The e*ac: 'engms can oe ceterminea Dy me cnan suoDnec witn eacn package of race SLIOE >sa Next, insert me wracoec ring into me stuffing oox ana tighten aown sufficiently on tne follower to compress me wrappea ring to 1/2 its original thickness. SLIDE >59 This same croceOure can oe usea m cacKing pumps or SLIDE >60 you may use creformec ring sets consisting of graphitic tape with praiaeo graphitic enc rings in the stuffing oox. your formeo ring will oe enaiess with no leakage paths ana wni oe a precise fit This is important m hign pressure applications wnere smaii iea*age paths can start a serious leak. iUOt * suoc *5* suoe SLlOf SLlOC K1 suoe ] 16 SLIDE ;5i 3e sure to rememoer mese imoortant nos Ail througn this presentation we ve used terras sucn as "higniignt" or "tics" or ' pointers'' Even tnougn we aon : "ave time to cover tnis very complex ana involved suDiec; m oetaiied fasnion mere are some very important iceas we c ine to leave with you The live woros you see nere -- Huid. temper ature. pressure, motion and size -- nave oeen mentioned tnrougnout tnis talk We repeat mem now oecause tney are tne five factors you must know oefore you can specify a packing' FLUID -- You nave to know if you are dealing with an aikanne an acid, or if it is a nigniy corrosive solution TEMPERATURE -- The packing you use has to oe ameto han dle the stuffing pox temperatures. PRESSURE -- if you nave hign pressure service you ocviously must work with different packing man wun tower pressure MOTION -- The revolutions per minute or strokes cer minute of a rod or shaft also ten you wnai you should or snouic not use as packing. SIZE -- Knowing the right size packing is casic Cut imoc'tart Oecause just one wrong dimension can give you a packing mat won't work Know your inside, diameter, outside diameter ana st uffmg cox depth and do away wun guesswork and ma in:e,~ance headaches SLJOE =62 After tnis very important information is known you ca" men consult me GARLCCK packing recommencation chart n tne "GARLOCK industrial Products Catalog ' SLIDE =63 At GARLOCK. packing is Our Ousmess We Supply pacx.ng to hundreds of plants like yours every day We ve seen cacmng proeiems of every imaginaoie type and have worked tocemer wun our customers to solve even me most difficult situations For assistance with a particular packing installation 03:1 cur inside Sales Department m Sodus. New York ' Compression packing maintenance tips Always try to have a spare set of packing m stock partic ularly for key pieces of eouipment. But don t overstock Store m a cool, clean place 2. If a long stuffing so* creates excessive heat, use a spacer m the oottom of the Dox to reduce the bumper of rings m the set. (See sxercn.) 3 In typical compression packing installation, most of the sealing m the stuffing oox .s cone Dy the ring next to the giano. Note wnere the wear usually occurs m the drawing at right. Be sure to compress the packing ring py ring to assure maximum sealing efficiency. 4 Clean the stuffing oox thoroughly after removing old pack ing. Also thoroughly clean ano polish the rod or snaft 5. Over-tightening is the greatest single cause of packing failure 5. LuOricate packing rings with GARIOCK LUBAU.f pack ing luoricant prior to assempiy. 7 When a packing set fails unexpectedly or after unusually short service life save it forme manufacturer to examine, it can tell a lot aoout operating conditions and aoout possi ble causes of failure. All slides. tapes and accompanying illuxtrationx ara the proparty o I GARLOCK INC and may not ba utad or duplicated without the expressed consent oI GARLOCK INC. Colt Industries GdrlOCk Inc Machanical Packing Divfalon Compraaaion Packing 300 All.flq O'** Sodut U15I G*noc im#mttonoj Owmaw Patmvre Now vorm G*no< of CAnooa lid . Towo Ormt* MlZ IH5