EMISSION CONTROL

Experiences performing
API standard 622
Type testing of process valve packing for fugitive emissions

mechanical cycling, corrosion, and metal specimen.These fixtures are stored

The publication of the API material makeup in an enclosure that is equipped with a
622 specification has marked • API-622: does not provide acceptance shelf, suspending the fixtures over a water
criteria for valve packing, nor is it bath, and ensuring a moist environment
a departure from the common
intended to replace proof testing of for the 28 day duration of the test.
method of evaluating packing
valve assemblies or valve production Following the 28 day exposure period the
performance as a part of valve testing metal samples are photographed. After
qualification tests. Instead, API The specification consists of three parts: they undergo an x-ray corrosion analysis,
622 evaluates packing fugitive emissions testing, corrosion testing, the amount and severity of corrosion is
performance in a standardized and materials testing. API-622 provides quantified in terms of percentage of
fixture, outside the influence very detailed specifications, descriptions, surface corroded, and mean and
of a particular valve’s design. and guidelines for both the test fixtures maximum pitting depth.
This article will outline the use and procedures.The following is a very
brief summary of these tests. • High temperature corrosion testing
of API 622 in tests performed
The high temperature corrosion test uses
by Yarmouth Research and 1. Fugitive emissions testing a fixture similar to the ambient corrosion
Technology. The general The fugitive emissions portion of the test test, except that the packing and metal
experiences performing API is performed on a test fixture that samples are subjected to demineralized
622 emissions tests were simulates valve packing gland conditions. water at a temperature of 300 deg F and
positive ones. This paper The fixture uses 97 % pure, dry methane 650 psig for 35 days.The same post-
describes the test procedures, as the detectable, pressurizing fluid. Over exposure analysis and measurements are
our results in performing the the course of the three day test, the performed.
packing gland is subjected to three
tests on a braided flexible
thermal cycles from ambient to 500 deg F, 3. Packing Materials Testing
graphite packing, and the
three pressure cycles from 0 psig to 600 • Weight Loss at Elevated temperature
lessons that were learned. psig, and 1500 actuation cycles. Each day, Packing samples are subjected to
250 actuation cycles are performed at progressively elevated temperatures (in
ambient temperature and 250 cycles are air) at 300, 500, 600, 700, 800, 900, and
By Chris Boss and James Drago, P.E. from Garlock performed at 500 deg F. Methane leakage 1000 deg F for one hour. After each
Sealing Technologies and Matt Wasielewski, P.E. is monitored by a flame ionization vapor exposure, the sample is removed from the
Yarmouth Research and Technology analyzer. Leakage is collected from around oven and any resulting loss of mass is
the stem/packing interface by way of a measured.
specially designed gland follower to which
Description of Test Procedures the detector is connected. It should be • Density
Several important distinctions set API 622 noted that none of the leakage from the Simple density measurements are
apart from other packing performance packing OD is collected. performed on a packing sample by
tests.The scope of the specification dividing the mass of the sample by its
highlights several of these unique points: 2. Corrosion testing volume.
• API-622: specifies requirements for The corrosion testing portion of the
comparative testing of block valve stem specification involves two different tests. • Lubricant content
packing for process applications where One test is performed at ambient Two tests are performed to determine
fugitive emissions are a consideration temperature, and the other at 300 deg F. lubricant content. First, the PTFE content
• API-622: is not simply a performance in the packing is determined by
test, but rather a range of tests that • Ambient temperature corrosion testing performing a total Fluorine content
evaluate many factors that are In the ambient test, a packing sample is measurement per ASTM D129 and
determined to affect fugitive emissions soaked in demineralized water and then D1179.The PTFE content can be derived
performance.These include: inserted into a small fixture that from the total Fluorine content.
temperature, pressure, thermal cycling, compresses the packing sample around a The second test is a solvent extraction

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EMISSION CONTROL
test used to measure wet lubricant Results
content in the sample.The procedure is Emissions test results
outlined in the specification.
Test Parameter Results of test 1 Results of test 2
• Leachables
Two ASTM standards are referenced in Average Test Pressure 602 psi (41.5 bar) 600 psi (41.4 bar)
API-622 to be used in measuring
leachable Chloride and Fluoride content; Number of Actuation Cycles Completed 1500 1500
ASTM D512 and ASTM D1179,
respectively. Number of Thermal Cycles 3 3

Lessons Learned Number of Packing Adjustments Required 1 adjustment 1 adjustment

Cycle at which adjustment occurred at cycle 600 at cycle 650
What was difficult? at ambient at ambient
For the emissions portion of the temperature temperature
specification the primary difficulty is the
daily duration of the test. With a cycling
Average Leakage Throughout Test 58 ppmv 41 ppmv
rate of 1 cycle per 60 seconds and a 2
hour heat-up time, an average test day is Maximum Leakage Throughout 877 ppmv 598 ppmv
about 12 hours. If another more massive
test rig were to be created, the heat up Results observed were consistent for the two tests run, indicating repeatability of the method.
time would be even greater.
For the Weight Loss portion of the tests with well defined procedures. measurement point at 1500 cycles after
materials testing, it is important to insure cooling to ambient temperature is
that the oven being used to heat the Recommendations recommend.This will complete readings
samples will provide an accurate and even Based on the experience with the for the 3rd thermal cycle.
temperature distribution throughout. specification there are several changes to • Further it is recommended that the
Testing of several samples is the test standard that we would like to primary and secondary thermocouple
recommended in order to insure that hot submit for consideration. positions be reversed.There are well
or cold spots in the oven do not affect • The addition of a final leak defined requirements for the
the test results.
Corrosion test results
What went well?
The emissions test fixture is well designed Temperature Metal not in contact Metal in contact with
with the leak probe at a fixed location. Condition and with packing packing
This provides repeatable results. Actuating Magnification
the stem by means of a hydraulic cylinder
provides fairly smooth motion.The flow
rate of hydraulic fluid needs to be Ambient
controlled so that actuation speed is kept 100X magnification
within the required limits.
The emissions test produced results that
are consistent in magnitude and in pattern
with other emissions test procedures Ambient
performed on the same materials. In many 200X magnification
emissions test procedures, using a wide
variety of materials, it is common to see a
leakage rate increase following the first
300°F (149°C)
thermal cycle.The same behavior was
100X magnification
noted in this procedure. Following a single,
allowable packing adjustment, leakage
control was sustained at very low levels
for the remainder of the test.This same 300°F (149°C)
behavior has been noted in other 200X magnification
emissions test procedures with this
material. No corrosion effects were noted on the metal samples in either the ambient or the high temperature corrosion tests.
The tests for Density, Lubricant Content, There were no notable visual differences between the surfaces in contact or not in contact with the packing. Because of
and Leachables are very straightforward this fact, quantification of corrosion products utilizing X-Ray diffraction was not performed.

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 EMISSION CONTROL
temperature and tolerance for the High Temperature Weightloss Results
primary thermocouple, where the
reference thermocouple has no such
requirements. The current version of
the standard has the primary
thermocouple position about 12 inches
away from the packing location, whereas
the reference probe is about 1 inch
from the bottom of the packing. With
the current configuration, the
temperature in the packing area can
vary by 20 deg C or more depending
upon heater and insulation position and
amount.This change would result in
better control of the temperature to
which the packing is exposed. (See
Figure bottom right)
• Although there is not a clear
recommendation, the current version
requires a long test day for laboratory
personnel, with a typical test running level to 50X will help to provide images chemical attributes. When combined with
about 12-14 hours. Readings are that will show the overall area more fire safe test specification such as API-589,
required about every hour. Possible clearly, while still being able to a very thorough assessment of packing
methods for reducing the daily duration differentiate corroded areas. It is felt that materials can be achieved.
of the test would include increasing the the 600X magnification is much too high The results can be used to effectively
speed of actuation or allowing • It is recommended that photos of the compare the relative performance of
actuations to continue during the corrosion test metal specimens be taken packing materials and configurations as
temperature increase from ambient to both before and after the test and that well as assess their strengths and
500 deg F the after photos should include areas of weaknesses in the areas of chemical purity
• The current standard does not measure the metal specimen that were both in and physical properties. While the
actuation force. While the test fixture contact with the packing and not in specification itself does not impose any
can handle high loads, excessive packing contact with the packing pass/fail criteria, it does provide a
friction can cause operating problems in consistent means of quantitative
valves. Opening and closing forces can Conclusions measurement.The user is free to
be easily calculated from the actuator The tests prescribed by API-622 provide determine what measured variables hold
pressure methods for the end user to evaluate the most significance for their application
• If the test standard is to be performed valve stem packing in three key areas; and whether they will set their own
on various sized fixtures, the standard emissions performance, corrosion minimum requirements.
should note that variations in the behavior, and general physical and
temperature rise rates are allowed. Also,
larger fixtures might require 2 days for
each thermal cycle
• The metal test specimens that are used
in the corrosion tests do not have a well
defined material specification. API-622
simply states: “sample steel rings shall be
machined from metal rods having the
same properties as the finished valve
stem”. While this does allow the user to
tailor the test to their own
requirements, it does not ensure that
results from various tests will be directly
comparable. In our test, 410 Stainless
Steel was chosen for the metal samples
• The corrosion test specification calls for
photos to be taken at both 100X and
200 X magnifications. It is recommended Cross sectional view of the API 622 Emissions test fixture. Thermocouple locations are noted as part 11
that a reduction in the magnification (by permission of The American Petroleum Institute)

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