Low Emission Graphite Packing Set, API 622, 65*85 mm, 45 MPa

Name: Low Emission Graphite Packing Set, API 622, 65*85 mm, 45 MPa
SKU: MV-20250625-GP-05
Availability: InStock
Rating: 5 (1 reviews)

Key Specifications / Features

The Low Emission Graphite Packing Set from our plant is engineered for superior performance and reliability. With an inner diameter of 65mm and an outer diameter of 85mm, this packing set features a minimum graphite purity of 99% and a 20% metal wire content, ensuring robustness and durability. Certified to withstand pressures up to 45 MPa, it meets stringent environmental and safety standards, including TA-Luft, ISO 15848, and API 622. This high-quality packing set is designed to minimize emissions and provide long-lasting, leak-free performance in critical applications.

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Detail Information

Product Name: Low Emission Graphite Packing Set
Model: M600
Size: ID 65mm * OD 85mm
Material Properties:
Graphite Purity: ≥99%
Metal Wire Content: 20% (Material options: Inconel 600 or 625)
Sulfur Content: ≤50PPM
Chlorine Content: ≤20PPM

Features: This engineering-designed low-emission/leakage valve packing set combines metal wire-braided enhanced expanded graphite rings with a highly adaptable core. The permanent elastic components in the sealing kit ensure minimal leakage and reduced friction throughout the valve's entire life cycle.

Operating Parameters

Speed: 2 m/s
Temperature Range: -200°C to +450°C (for most media), -200°C to +550°C (for steam)
pH Value: 0 to 14
Pressure: 45 MPa
Media: Steam, gas, alkali, oil, acids, oil, hydrocarbons
Certifications/Licenses: TA-Luft, ISO 15848, API 622
Except for strong oxidizing acids, such as sulfuric acid and nitric acid.

Advantages

High-temperature resistance and chemical resistance
Fully compliant with the latest fugitive emission regulations
Superior sealing performance and permanent elasticity
Excellent anti-extrusion properties under high pressure
Optimized ring configuration requires lower compressive force

Low Emission Standards

1. ISO 15848

ISO 15848 standardizes the measurement, testing, and evaluation procedures for industrial valve fugitive emissions. This standard is divided into two parts. ISO 15848-1 defines the test procedures for valve type testing, and ISO 15848-2 specifies the requirements for the manufacturing of valve products.

2. TA- LUFT (VDI 2440)

The German fugitive emission control law TA-LUFT VDI2440 defines the leakage rate, testing, and testing methods.

3. VDI2200, VDI2440 and TA- LUFT Flange Connection

According to TA-LUFT and VDI 2440, the flange connection must meet the test pressure of 1 bar under the condition that the leakage rate is less than 10−4 mbar × l/(s × m). VDI 2200 specifies the selection, calculation, design, installation, and testing process of the flange connection. It also allows reference to VDI 2440 for the leakage rate. VDI 2200 also stipulates the burst pressure test to avoid the risk of flange breakage and sudden leakage.

4. CLEAN AIR ACT

The Clean Air Act stipulates that the maximum allowable leakage rate for valves, pumps, and agitators in the United States must comply with the EPA Method21 (blower method) for leakage testing, and the testing method must be consistent.

5. API 622

API 622 is the second edition of the international performance test for disk root materials, which includes temperature, pressure, thermal cycles, and mechanical cycles. API 622 specifies 1510 mechanical cycles and 5 thermal cycles, from room temperature to 260°C (500°F), pressure from 0 to 600 psi (0-41bar), for high-temperature testing. Under carbon equivalent testing, the allowable leakage rate is 100 ppm.

6. API 624

The first edition of the API 624 standard for the type test of the fugitive emission of the valve with a graphite seal includes the up and down motion and rotation of the valve, with a maximum diameter of 24 inches. The test requires the temperature to rise to 260°C (500°F) and perform 310 mechanical cycles and 3 thermal cycles, with the maximum allowable leakage rate being 100 ppm. The valve to be tested must first be tested according to API 622, and the temperature range is from -29°C to 538°C (-20°F to 1000°F).

ISO 15848 Sealing Grades

Grade	Leakage Rate	Remarks
A (Gas only)	≤ 10−6 mg / (s × m)	Generally, valves with bellows seals or double seals can reach this grade
B	≤ 10−4 mg / (s × m)	Generally, PTFE lined valves with good sealing (such as diaphragm valves) can reach this grade
C	≤ 10−2 mg / (s × m)	Generally, valves with soft sealing materials can reach this grade

VDI2440 Specifies the Maximum Leakage Rate of Valves with Harmful and Combustible Substances

Temperature	Leakage Rate
< 250°C	≤ 10⁻⁴ mbar × l / (s × m)
≥ 250°C	≤ 10⁻² mbar × l / (s × m)

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FAQs

What are Low Emission Valves?

Basic Concept

Low Emission Valves refer to valves that, through special design and manufacturing processes of the stem packing and mid-seat gasket, control the leakage of media (gases, liquids) to extremely low levels. They are primarily used in industrial scenarios with high safety and environmental protection requirements. The core objective is to reduce or prevent the leakage of harmful media (such as volatile organic compounds (VOCs), toxic gases, flammable and explosive substances, etc.) into the external environment. Therefore, low emission valves offer multiple advantages in terms of energy conservation, emission reduction, reduced safety risks, and environmental pollution.

Key Technical Standards and Leakage Grades

The performance of Low Emission Valves is quantified by their leakage rate, and different industries follow different standards. Common standards include:

1. International Standards

ISO 15848-1: This standard classifies valve leakage grades into four levels: A (the highest requirement), B, C, and D. Grade A requires a leakage rate of ≤100 ppm (by volume).

API 624 (American Petroleum Institute): This standard, applicable to the refining and chemical industries, specifies a leakage rate of ≤100 ppm (for gases) under specific pressures.

EPA Standard (U.S. Environmental Protection Agency): This standard, targeting VOC emissions, requires a leakage rate of ≤500 ppm.

2. Chinese Standards

GB/T 42223-2022: This standard, which references international standards, regulates the design, manufacturing, and testing of Low Emission Valves.

Traditional Valves vs. Low Emission Valves

Comparison Dimension	Traditional Valves	Low Emission Valves
Leakage Rate	Typically ≥1000 ppm (for gases)	≤100 ppm (some can reach ≤10 ppm)
Sealing Structure	Single seal (e.g., packing gland) with poor initial stability, susceptible to temperature changes and impact	Single seal (e.g., packing gland) with long-term extreme stability, unaffected by temperature changes and impact
Testing Requirements	Hydrostatic / Pneumatic tests	Helium leak detection (leakage rate ≤1×10⁻⁷ Pa・m³/s)
Cost	Lower	Slightly higher, but less than 1-2% more than traditional valves
Applicable Media	General industrial fluids	High-risk, high-value, and high environmental protection requirement media

Storage Performance Deficiencies of Traditional Valves

Traditional valves using ordinary graphite packing face dual storage risks.

1. Physical Adsorption Leading to Operational Failure

During long-term static storage, graphite molecules adhere to the valve stem surface due to van der Waals forces, forming a rigid adsorption layer. This increases the valve opening torque by 2-3 times compared to the initial value. In extreme cases, it may cause the actuator to overload and fail.

2. Chemical Corrosion Leading to Seal Degradation

Ordinary graphite packing typically has a sulfur content of ≥1200 ppm (by mass). In storage environments with humidity ≥60%, sulfur reacts with the metal valve stem through electrochemical corrosion, forming a FeS corrosion layer. This enlarges the seal interface gap, causing the leakage rate to increase exponentially over time, with an average annual leakage increase of 30%-50%.

Storage Performance Advantages of Low Emission Valves

Low Emission Valves achieve a breakthrough in storage stability through the following means:

1. Upgraded Material System

Sealing Packing: High-purity sulfur-free graphite (sulfur content ≤0.01%) with ≥99.5% purity is used. The interlayer bonding is enhanced through nano-scale flake orientation technology, blocking the migration path of sulfur elements.

Mid-flange Gasket: Modified flexible graphite composite material with 15%-20% nickel-based alloy reinforcement is used to form a corrosion-resistant skeletal structure.

2. Performance Verification Data

Traditional Valves: Opening torque increases from 80 N•m to 220 N•m, and leakage rate rises from 500 ppm to 2800 ppm.

Low Emission Valves: Opening torque fluctuation is ≤±5%, and leakage rate remains below 20 ppm, fully meeting the stringent long-term storage performance requirements of API 624.

How We Manufacture 100% Low Emission Valves?

At first, manufacturing low emission valves was pretty much the same for us as it was for other regular valve manufacturers in China. If we ran into problems like valves not passing tests or having leak rates that kept changing, we'd just try to get better packing materials from a different supplier. We didn't really stop to think about the bigger picture, like how the whole manufacturing process or the properties of the materials we were using might be causing the issues.

Over time, we figured out that the metal parts of the valves were pretty reliable, but we hadn't been paying enough attention to the non-metal parts that actually do the sealing. And those parts are super important for making sure the valves don't leak. So, back in 2008, we decided to focus on manufacturing low emission valves from start to finish.

First, we created a special team just for figuring out better ways to seal valves. They dug deep into how to make the seals work really well and how to build them. At the same time, we started working closely between the people who design the seals and the people who manufacture the valves. By tweaking the design of the seals and how we put the valves together, we made a system where everything works together perfectly. After that, we tested a bunch of different valves to see how well they sealed in all kinds of situations: different sizes, pressures, and temperatures. All the data we collected from these tests helped us keep improving our valves.

Now, when we manufacture a bunch of valves and check them randomly, they all meet the tough standards of API 624 and ISO 15848-1. We've gone from just following a process to really understanding and controlling the technology ourselves.