Environmental emissions control

How James Walker can help your business

A guide to effective sealing systems fromthe James Walker Group

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Contents

Section 1 James Walker Group

About James Walker . . . . . . . . . . . . . . . . . . . .4

Leading with Technology . . . . . . . . . . . . . . . .6

Industry Focus . . . . . . . . . . . . . . . . . . . . . . . .6

E-business to meet you objectives . . . . . . . . .7

Your global partner in selling success . . . . . .7

An Overview of the EU Integrated PollutionPrevention and control (IPPC) Regulations . .8

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Section 2How James Walker can help

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .9

James Walker products . . . . . . . . . . . . . . . . .9

Compression packings for valves . . . . . . . . .9

•Metakamm® Kammprofile

•Metaflex®

•Metcom® gaskets

•GORE® Universal Pipe Gaskets

Bolted Joints . . . . . . . . . . . . . . . . . . . . . . . . .13

Ensuring joint tightness . . . . . . . . . . . . . . . .13

RotaBolt® tension control fasteners . . . . . . .13

•RotaBolt® 1

•RotaBolt® 2

•RotaBolt® Vision

Supagraf Tanged T10 . . . . . . . . . . . . . . . . . .15

Supagraf Laminated N7 . . . . . . . . . . . . . . . .15

Fluolia Integra Blue . . . . . . . . . . . . . . . . . . . .16

Fluolion Integra White . . . . . . . . . . . . . . . . . .16

Gasket Cutting Service . . . . . . . . . . . . . . . . .18

Custom- cut gaskets . . . . . . . . . . . . . . . . . . .18

Support Services . . . . . . . . . . . . . . . . . . . . . .19

Joint Integrity Programme . . . . . . . . . . . . . .19

•LDAR (Leak Detection and Repair) services

•Data management and reporting

•Heat exchangers and pressure vessels

•Plant maintenance & refurbishment

In conclusion . . . . . . . . . . . . . . . . . . . . . . . . .21

Typical scenario . . . . . . . . . . . . . . . . . . . . . .22

Case study . . . . . . . . . . . . . . . . . . . . . . . . . .22

Information . . . . . . . . . . . . . . . . . . . . . . . . . .23

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James Walker is a dynamic global

manufacturer and distributor that supplies

a vast range of standard and specialised

products and services to virtually every

industrial sector.

James WalkerSection 1

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Our world-leading expertise and capability inhigh performance fluid sealing and boltingtechnology, led by design and materialstechnology, embraces the complete industrialcycle from research, development andmanufacture, to product application,maintenance and equipment refurbishment. These activities help keep global industryrunning safely, efficiently and with improvedenvironmental performance, year-in, year-out.

We serve customers in over 100 countriesthrough our extensive production,engineering, distribution, technical supportand customer support facilities - backed by ITnetworks, e-commerce systems and logisticsoperations.

Quality - the primeconsiderationQuality design, quality manufacture andquality service are paramount throughout ourworldwide operations. We start with the bestraw materials and use advancedmanufacturing techniques with strict qualitycontrol. This culture is reinforced by top-leveltechnical support, our logistics network anda multitude of customised services.

Our quality standards are third partyregistered to BS EN ISO 9001:2000. Industrybodies such as API, as well as corporations,utilities and government organisations,regularly assess and approve our standards.

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Leading with technology By operating at the leading edge of technology,we ensure that our products and servicesmatch the ever-growing complexity of industrialplant - both for today and into the future.

Fluid sealing is not a stand-alone technology: itis based on materials development, innovativedesign and skilled application. It dependsgreatly on constant advances in elastomers,engineering plastics, metallurgy andmanufacturing techniques, as well as chemistry,tribology and fastener technology.

We make best use of these capabilities to helpindustry improve its safety, environmental andrevenue protection. Many of our productsefficiently control fugitive emissions of volatileorganic compounds to TA-Luft and otherstandards. We also provide specialisedknowledge and products to companies thatmust meet the latest environmental legislation,such as the European Union's wide-rangingIntegrated Pollution Prevention and Control(IPPC) directive 96/61/EC.

Industry focus We have top technical specialists dedicatedto specific industry sectors where they adviseon the application of fluid sealing andassociated technologies.

The industries we serve in this way include:chemical and petrochemical, defence andaerospace, engineering and manufacturing,marine, metallurgical, mineral extraction,nuclear, oil and gas, pharmaceutical andfood, power generation and supply,renewable energy, rail, semiconductors andelectronics, and water and waste.

James Walker

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E-business to meet yourobjectives At the heart of our major partnering contractsis an e-procurement system for transactingbusiness by electronic means on a globalbasis. This fast, flexible service improvessupply chain efficiency and reducesstockholding costs for customers. Cataloguecontent is the key to e-procurement success.We create catalogues in many languages,listing all our products and services neededby the customer. Orders can be tracked,stock levels checked, prices verified, andshipping status and delivery dates confirmed.Supply accuracy and security areunparalleled, and paper trails eliminated.

Your global partner in sealingsuccess Our role as a global supplier demands aninternational manufacturing base, plus highlyefficient sales and distribution operations. Wehave a worldwide family of companies with over50 production, engineering, distribution andcustomer support sites spread across Europe,Australasia, Asia Pacific, Africa and the Americas.

At the local level, a close-knit network ofJames Walker companies and officialdistributors supplies our products and servicesto well over 100 countries. Our IT systems andlogistics operations give customers the suretyof supply they need.

We work in close partnership with customersat all levels. The long-term contracts we forgewith multinational corporations cover therequirements of their plants across manycontinents. Major players in the metallurgical,power generation, chemical and petrochemicalprocessing sectors rely on sole-supply dealswith James Walker companies and thetechnical support we provide.

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An overview of the EUIntegrated PollutionPrevention and Control(IPPC) regulations The IPPC Directive 96/61/EC was adopted inthe European Union September 1996 andbecame law in October 1999. This is the firstsingle environmental legislation which takesan integrated approach on emissionsincluding noise, vibration and heat, energyefficiency, water efficiency, waste production,land contamination, emergency preparedness,accident prevention and managementsystems, in addition to emissions to theenvironment.

Another innovation is the introduction of theconcept of BAT (Best Available Techniques).BAT can apply to either a product or service.Applicants and regulators have to assess whattechnology is used and how their currentsystems and procedures impact onenvironmental protection. Companies will beobliged to use BAT, but to do that, informationon new technologies and techniques needs tobe established.

James Walker is an active member of theEuropean Sealing Association and we havemade a significant contribution to theAssociation's 'Sealing Technology BATGuidance Notes'. This document, which isavailable for free download from the ESAwebsite, gives consensus guidance on BestAvailable Techniques for sealing; boltedflange connections, rotodynamic equipment,reciprocating shafts and valves. We arecertain that the information contained in thisdocument will prove valuable for companiesoperating outside the EU.

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IntroductionJames Walker's great strength is the provisionof world-beating solutions to control andeliminate VOC emissions, particularly inrefineries, petrochemical, chemical and otherareas of the process industries.

VOC is the generic term applied to allcompounds containing organic carbon, whichevaporate at ambient temperature andcontribute to the formation of 'summer smog'and odour nuisance.

As a world leader in sealing solutions, wehave an in depth understanding of the latestsealing technologies and products and canconfirm whether the sealing systems youhave, or are planning to install, meets youremissions containment targets.

We also have a range of highly professionalservices including plant maintenance andrepair and our new Joint Integrity Programmewhich includes a comprehensive leakdetection and repair service for VOCs.

James Walker productsWe have an extensive range of world-classproducts and services which meet or exceedthe requirements of many internationalstandards, including the requirements of theGerman 'TA-Luft'.

In addition to helping ensure effective andefficient emissions control, James Walkerproducts can also significantly reduce energyconsumption and costs.

Compression packings forvalvesEquipment leaks from valve glands areconsidered to account for approximately 50-60% of the fugitive emissions on petrochemicalsites. Furthermore, the major proportion offugitive emissions comes from only a smallfraction of the sources. For example, less than5% of valves in gas / vapour service canaccount for more than 90% of the fugitiveemissions in a refinery.

James Walker offers two products - Supagraf®

Premier and Supagraf® Control - which werespecifically developed through intensiveresearch programmes to combat fugitive VOCemissions from valves.

How James Walker can helpSection 2

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Supagraf® Control – for controlvalves – high cycle duty sealing withgood fugitive emission control

• High integrity gland sealing for controlvalves

• Reduces fugitive emissions to below 50ppm

• Certified to TA-Luft requirements

• Long-term, adjustment-free operation - over100,000 valve strokes

• Low friction graphite for accurate valve action

• Maximum system pressure: typically 210bar

• Has been tested in a control valve to therequirements of ISO 15848-1 and achievedclass B tightness levels over 100,000 cycles

Supagraf® Premier – world-beating fugitive emission control for block valves

• Fugitive emission control to well below100ppm

• Certified to TA-Luft requirements

• Low friction on rotary and rising stem valves

• Maximum system pressure: typically 210bar

• Has been testing in a valve in accordancewith Shell spec SPE77/312 and achievedclass A tightness

• Top of its class in independent tests run onbehalf of the CAPI Group (Akzo Nobel,Shell, Dow and DSM)

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Flange Gaskets & SheetJointingsA significant majority of VOC fugitiveemissions come from petrochemical processequipment. In addition to a wide range ofquality sheet gasket materials such ascompressed fibre and expanded graphite,James Walker also offers four world-beatingsolutions - Metakamm® Kammprofile,Metaflex® spiral wound gaskets, Metcom® anda range of WL Gore & Associates PTFE gasketproducts. A range of sheet jointing materials,including expanded graphite, is also available.

Metakamm® KammprofileOur Metakamm® Kammprofile gaskets arenow widely specified for hightemperature/pressure pipework, heatexchangers and other pressure vessels wherespiral wound gaskets were previously used.The structure involves a robust metal core witha soft layer of sealing material bonded toconcentric grooves on either side. These areeasier to handle at large diameters, whereasrough handling can often cause a largediameter spiral-wound gasket to spring apart.

Prime features

• Accommodate a vast range of operatingconditions including line temperatures up to1000°C and pressures typically up toaround 250bar

• Used on vessels such as heat exchangerswhere thermal cycling exists, and wherejoints need to be made quite rigid for bestresults

• Undamaged cores can often be fitted withnew soft faces to reduce maintenance costs

• Certified as meeting TA-Luft emissioncontrol requirements

• Manufactured to suit all relevant flangestandards including ASME B16.5, BS1560,ASME B16.47 Series A (MSS-SP44), ASMEB16.47 Series B (API605), BS EN 1092(BS4504); plus DIN, JIS and NF

Metaflex®

Typically Metaflex® spiral wound gaskets areused on pipelines and pressure vessels onsteam, petrochemical, nuclear, marine andhydraulic plant, and heat exchangers.

Metaflex® gaskets are manufactured from V-shaped metal strips, spirally wound with aninlay of filler between each turn. Support rings,inside and/or outside the spiral, improve thegasket's handling, fitting and versatility. Thisarrangement is highly successful on flangeswhere temperature, pressure, vibration or flowrates are beyond the capability ofconventional jointing materials.

Prime features

• A wide variety of sizes and shapes

• Combinations of metal strip and filler areselected to suit the specific fluid media andoperating conditions

• Quick to install and remove

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• Operating temperatures from cryogenic upto 1000°C

• Ability to cope with thermal cycling conditions

• System pressures from high vacuum to over 350bar

• Support rings - inside and/or outside thespiral - make gaskets suitable for highpipeline pressures on flat or raised flangefaces

• Certified as meeting TA-Luft emissioncontrol requirements

• Manufactured in accordance with all relevantgasket standards to suit flange designations:ASME B16.5, BS1560, ASME B16.47 Series A(MSS-SP44), ASME B16.47 Series B(API605), BS EN 1092 (BS4504); plus DIN,JIS and NF

Metcom® gasketsSelf-locating Metcom® gaskets are suitable forhigh temperatures and pressure applications,and are particularly effective when used toreplace thinner pipe joints used inpetrochemicals liquid or gas production andtransportation.

Prime features

• Thin corrugated steel with concentric grooves

• Grooves filled with expanded graphite

• Lug design for easy fitting with self-location.The multi-fit lug design means a reducedinventory as one size fits several flange classes

• Thinner than a spiral wound gasket, whenreplacing compressed fibre gaskets usedpreviously

• Certified to TA-Luft requirements

GORE® Universal Pipe GasketsGORE® Universal Pipe Gaskets (Style 800) areused to seal all types of flanges in chemicalprocess piping. Designed to meet the needsof many different piping materials, they areideal for standardising gasket material acrossthe steel, glass-lined steel and FRP systems,whenever a non-metallic gasket can be used.GORE® Universal Pipe Gaskets meet TA-Luftrequirements.

Other Jointing MaterialsIn addition to its range of gaskets, JamesWalker offers a complete range of sheet jointingmaterials, including expanded graphite.

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Bolted Joints

Ensuring minimum leak riskConventional bolt tightening methods oftenleave a lot to be desired. Relying on torquemeans that the relationship between tighteningpower and achieved tension in the fastener hasto be estimated, as the frictional properties onthe threads and washers cannot be guaranteed.

Similarly, devices such as hydraulic tensionersuse an estimated degree of overload to try andcompensate for compliance in the system whenthese tensioners are de-pressurised.

The only way to ensure minimum leak risk is toinstall joints to the optimum loading. To achievethis, you need a way of actually measuring theinstalled fastener tension load with some degreeof accuracy. Tension control is critical to thereliability and safety of bolted joints.

Traditional tightening methods measure thesecondary factors of torque or hydraulicpressure - they do not measure the key factor-tension! RotaBolt® delivers tension control atinstallation and throughout the life of the boltedjoint, providing simple, accurate and continuousverification of pressure on the gasket

RotaBolt® tension controlfastenersThe James Walker RotaBolt range of tensionmonitoring systems and unrivalled technicalexpertise has established the company as aglobal centre of excellence for boltingtechnology. We provide solutions across awide range of industries including oil and gas,chemical processing, power generation, civilengineering, environment, transport anddefence.

Incorporating RotaBolt® technology intoproduct design delivers significant benefitsfrom health & safety and environmentalperspectives. The accuracy of gasket pressurecontrol made possible by RotaBolt technologyhas been shown again and again to delivercost savings through reduced maintenanceand down time. The installation of gasketscombined with RotaBolts is now playing animportant role in maintaining operationalreliability across a vast range of industries.

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RotaBolt® 1The RotaBolt® tension sensor design has beenproven in the most arduous of applications forover 25 years. Every RotaBolt is 100% load testcalibrated to an accuracy of 5% on tension.Standard bolts are converted by inserting theRotaBolt indicator. Component materials arecompatible with the parent bolt to nullify in-service thermal and galvanic effects.

Before bolt installation, the special rotacapspins freely. As the bolt is tightened, itstretches elastically and the rotacap locks atthe specified calibrated tension value. Iftension reduces for any reason, the rotacapimmediately rotates freely to give a clearindication of tension loss.

RotaBolt® 2RotaBolt® 2 provides an additional tensioncontrol on installation tightening and in-servicechecking, by offering two tension settings in asingle sensor. A dual load indicator cap - theouter cap for high-tension setting and theinner cap for low tension - gives the choice ofan operational tension range, either foroverload or maintenance control.

RotaBolt® VisionRotaBolt® Vision is the world's first safety bolt togive a clear, visual indication of loss of tensionacross the bolted joint. It operates on the sameinternal air-gap sensor technology as RotaBolt®

1, but instead of a tactile, fingertip indicator,RotaBolt Vision has a specially developed visualindicator which appears as an unbroken yellowline across the head of the bolt.

As soon as tension is lost across the bolt, theindicator instantly rotates by ninety degrees toshow a distinct right angle break in the yellowline. This is clearly visible up to 25 metres away.

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Supagraf® Tanged T10 – We willalso need to mention about ourgasket cutting service especiallywhen we talk about Supagraf®

Tanged T10.

Description Sheet jointing of 98% pure exfoliated graphitereinforced with a central layer of 0.1mm thicktanged stainless steel. The graphite iscompressed onto the perforated metal sheet togive a secure mechanical lock withoutadhesive.

Prime Features• Exceptional resistance to blow-out and

crushing

• Extra strength for ease of handling and fitting

• Anti-stick coating available

SpecificationBAM-approved for use with liquid and gaseousoxygen in flange connections of copper, copperalloys or steel at operating conditions up to130bar and 200°C.

Service CapabilityFor applications falling into the green zone, theproduct may normally be used withoutconsultation. In the amber zone, werecommend that our technical services team iscontacted for confirmation of suitability. If thepressure/temperature combination is in the redzone then we must be consulted before theproduct is used. Class lines refer to ASMEB16.5. For inert/reducing media the maximumtemperature is 700°C, but ensure thattemperatures above 400°C on atmosphere sideof flange do not cause gasket to oxidiseinwards from the outside edge. Minimumoperating temperature is -200°C.

Supagraf® Laminated N7

Description Sheet jointing of 98% pure exfoliated graphitewith a bonded central layer of nickel foil.

Prime Features• Extra strength for ease of handling and fitting

• Excellent sealing integrity

• Can be cut with hand tools

Physical propertiesTypical values for 1.5mm thick sheet

• Density (graphite): 0.7 mg/m3

• Compressibility: 45% (ASTM F36A)

• Recovery: 17% (ASTM F36A)

Service Capability• Maximum temperature (oxidising media):

400°C

• Maximum temperature (*inert/reducing media): 1000°C

(*Ensure that temperatures above 400°C onatmosphere side of the flange do not causethe gasket to oxidise inwards from the outside edge.)

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Fluolion® Integra Blue

Description General purpose PTFE-based sheet jointingspecially stabilised and mechanically treated toimprove multi-directional strength, combatcreep and improve resilience for flange jointing duties.

Typical Applications Flanged joints on plant that handles aggressivefluid media, especially where hygiene is toppriority - such as in the pharmaceutical, foodand electronic industries. It is especially suitedto applications with weak or lightly loadedflanges, as well as standard flange duties.

Prime FeaturesHighly recommended for duties with causticalkalis and strong acids, at elevatedtemperatures and moderate concentrations.High compressibility for effective sealing onlightly loaded flanges. Outstanding resistanceto a very wide range of chemical media.Inherently clean, non-toxic and non-tainting.Can be used at cryogenic temperatures.

SpecificationsComplies with requirements of FDARegulations for food use. WRAS-approved foruse with hot and cold potable water up to 85°C.

Fluolion® Integra White

Description Specially stabilised PTFE sheet material,mechanically treated to improve multi-directional strength, combat creep and improveresilience for flange jointing. It was previouslydesignated Fluolion® Integra.

Typical Applications Flanged joints on plant that handles extremelyaggressive fluid media. Also where hygiene istop priority - such as in the pharmaceutical,food and electronic industries.

Prime FeaturesHighly recommended for duties with strongacids and oxidising agents at elevatedtemperatures and all concentrations.Outstanding resistance to a very wide range ofchemical media. Inherently clean, non-toxic andnon-tainting. Can be used at cryogenictemperatures. Displays compressibility andrecovery characteristics close to those of manynon-asbestos fibre jointings.

SpecificationsComplies with requirements of FDA regulationsfor food use, and USP 25, Class V classificationof plastics for pharmaceutical service. WRAS-approved for use with hot and cold potablewater up to 85°C.

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Gasket cutting service

Immediate supply James Walker is dedicated to meetingindustry's immediate demands for precision-cutgaskets from sheet jointing materials, as well asfor spiral wound and metallic types.

Our automated distribution centres hold tenmillion sealing products ready for same daydispatch throughout the world. A vast numberof these stock items are gaskets to suit flangesacross all sectors of industry.

If we do not have your gaskets in stock, wecan usually manufacture them economicallywithin minutes.

For this we use highly accurate CAD/CAMcontrolled water-jet cutters, ready programmedwith every gasket design to national andinternational standards. We hold large stocks ofnon-asbestos sheet jointings, rubber andSupagraf® products in all standardthicknesses, specifically for this purpose.

Custom-cut gaskets

Using the same technology enables us to makeany shape, size and quantity of non-standardcut gaskets to high precision standards - andmeet seemingly impossible deadlines.

We work directly from customers' CAD/CAMfiles, sent on disk, CD or e-mail. In addition, wecan digitise profiles from drawings, samples ortemplates - no tooling is needed.

Our state-of-the-art water-jet cutters operatewith all major CAD languages. Nesting patternsoftware, combined with video acquisitionequipment to capture the shape of a sheet,ensure the maximum number of gaskets isproduced with minimum wastage.

These systems prove highly economical forprototype cutting as well as large batch runs.

For metallic materials, such as Supagraf®Tanged Jointing T10, we use an abrasive water-jet cutter. This slices intricate designsfrom the toughest materials - including alloysteels and titanium - leaving a perfectly cleanedge without heat distortion. Each hair thinwater jet is loaded with crushed garnet andoperates at Mach 2 and 4000bar.

Noise limiting products

James Walker Group company, Tiflex, offers arange of impact and airborne attenuationproducts. These include Acoustic Barrier, arange of acoustic underflooring designed tosuit applications in new and refurbishmentprojects, Trackelast Attenuate (@~10~u~8)which deadens rail noise and vibration by up to6dB and the TICO range of products whichincludes anti-vibration materials for machineryand construction applications.

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Support Services

Joint Integrity Programme The James Walker Joint Integrity Programmehas been developed to support assetmanagers by offering an integrated andengineered approach to the provision ofadvanced sealing solutions.

Old equipment is updated or replaced andnew equipment added to keep pace withchanging market conditions and the demandsof environmental legislation.

Frequently, the result is a tangle of pipe-workand equipment from different manufacturers –and even different eras - bolted together. For anasset manager, ensuring all of these bolted jointsremain intact and leak-free can be a nightmare.

Bolted joints are sometimes a low prioritywhen it comes to maintenance planning. Thefocus of most maintenance schedules is onthe large – and expensive - equipment on site.It is only when there is a failure and expensiveproduct is pouring down the drain that thevalue of joint integrity is really appreciated.

The purpose of our Joint Integrity Programmeis to re-align that focus, by drawing on the

combined expertise of all the companies withinthe James Walker Group, from bolting throughto gasketing and project management.

To support the programme, we have enteredinto a series of strategic alliances which willprovide specific benefits to our clients.

The Joint Integrity Programme approach -Evaluate, Design and Apply - is aimed atdelivering long-term solutions where the costbenefits speak for themselves, as opposed toshort-term fixes that need to applied again andagain, at considerable cost.

We recognise that no one solution will beapplicable to everyone. The Joint IntegrityProgramme is made up of a series of modulesthat can be tailored to suit each individualclient’s needs and requirements. Some ofthese modules are outlined below.

• Leak Detection and Repair (LDAR ) forvessels handling volatile organic compounds

• Tagging, data management and reporting

• Heat exchanger and pressure vessel boltedjoint programme

Clients can choose a single service or acombination of services to best meet their needs.

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LDAR (Leak Detection andRepair)Our LDAR service combats fugitive VOCemissions at oil, gas and chemical sites. Wemonitor all piping components, flange jointsand valves to EPA Method 21, then record andtrack VOC emissions. We can assist inscheduling repairs and carry out maintenanceor refurbishment work. We then undertakeregular site audits to ensure the lowestpossible emission levels.

There are many additional benefits associatedwith our LDAR programme. For example,LDAR assists with environmental reporting andalso interfaces with your general maintenanceactivities.

LDAR will:

• Reduce your operating costs

• Stem your loss of valuable products

• Improve your environmental performance

• Enhance the safety of your on-siteoperatives

Data management andreporting A crucial part of the James Walker service isthe collection of data from the client's sitewhich can then be used to produce reportswhich support their emission control orgeneral business plans.

Heat exchangers and pressurevesselsHeat exchangers and pressure vessels carry ahigh risk of VOC leaks. We will evaluate, report,and provide an engineered solution, which caninclude analysis, on-site measurement,machining, dismantling, the installation ofproducts and components and ongoing, on-sitesupport. By choosing a tailored solution, youincrease production levels, reduce downtimeand cut maintenance costs.

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Plant maintenance &refurbishmentJames Walker companies also supplyindustry worldwide with professional plantmaintenance and refurbishment services thatgo well beyond the accepted norms in termsof advice and planning, the quality of on-siteand off-site workmanship and the standardsof safety and care.

Our on-site maintenance capabilities includethe overhaul of plant, such as pumps, valves,mixers, hydraulic equipment and flangejoints, together with the replacement ofexpansion joints and bellows.

We refurbish any model of industrial valve,pump, hydraulic cylinder or mechanical sealat our dedicated workshops. Another JamesWalker speciality is the overall re-engineeringof sealing systems, where we providemetalwork conversions for rotary equipmentto facilitate improvements and accommodatenew seal designs.

In conclusionJames Walker has the products, expertise andintegrated sealing solutions to save you timeand money when planning and implementingyour emission control plans.

James Walker products and services can helpcut equipment leaks dramatically and achieveefficiencies through reduced powerconsumption, better use of energy, improvedwater usage and better plant performance.

James Walker repair and maintenance servicescan ensure your emissions control targets aremaintained and that your plant operates in themost effective and efficient way.

In essence, the James Walker mission is toprevent pollution of the environment through arange of products and services which areenvironmentally friendly and which generatemajor benefits for your business.

Case study

Engineers at a large urea plant in NewZealand had struggled to curb leakage from aflange for no less than 10 years before ourlocal operation finally solved the problem. Theparticular joint was the dome flange on a highpressure decomposer reboiler lid. Despite theengineers' best efforts, this flange leakedcontinuously, even after shutdowns when thejoint had not been broken.

The hazardous nature of the product - ureacarbamate solution at 185°C - eliminated anyprospect of re-tensioning the bolts while theplant was operational. After discussions with thesite engineers, our gasket experts checked theflange gasket calculations and devised asolution - a PTFE-faced Metakamm® gasket fromthe James Walker Moorflex range, combinedwith 36 RotaBolt-controlled tension studs.

After these had been installed and correctlytensioned, the joint was monitored. It wasdiscovered that the gasket relaxed after 12hours at ambient temperature; something theplant engineers hadn't previously taken intoaccount. Spotting this change in joint integritywas made simple by the RotaBolts whichimmediately reacted to the altered tension.

It was then only a matter of re-tensioning eachRotaBolt® to solve, in a matter of hours, aproblem that had baffled engineers for adecade. Since the new joint was made, thepreviously troublesome vessel has beenopened up no less than four times forcleaning, with no signs of leakage when theprocess has been re-started.

Typical scenario

On more than one occasion,

James Walker has been presented

with a leaking pressure vessel in

hydrocarbon service, where there

has been a risk of fire due to the

escape of hot VOC products. In

such cases a 'steam quench' is

used to surround the flange to

flush the vapours out of the

atmosphere to try and mitigate the

obvious risks. By using good

bolted joint technology, quality

gaskets and accurate loading with

RotaBolts, these joints have

remained leak-free, giving the

following advantages:

• Reduced VOC product losses, hencereduced lost product cost and improvedenvironmental performance

• Reduced water consumption byreducing the need for the steam quench

• Reduced power consumption and costsby removing the need to generate steamfor the steam quench

• A safer working environment for theplant operators

• Removal of the need to apply short-term,costly, repetitive maintenance work

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Information This booklet is given for information purposes only. While we have taken every care to ensure that the information contained in this booklet is accurate and up to date, you should always obtain specific and expert advice before taking or refraining from taking any action. We will not accept any liability whatsoever for any losses, damage or injury whether financial or otherwise which any person may suffer as the result of acting or refraining from acting solely on the basis of the information contained in this booklet.

Health warning: If PTFE or fluorocarbon (FKM) products are heated to elevated temperatures, fumes will be produced which may give unpleasant effects, if inhaled. While some fumes are emitted below 250°C from fluorocarbons or below 300°C from PTFE, the effect at these temperatures is negligible. Care should be taken to avoid contaminating tobacco with particles of fluorocarbon or PTFE or with PTFE dispersion, which may remain on hands or clothing. Material Safety Data Sheets (MSDS) are available on request.

Information in this publication and otherwise supplied to users is based on our general experience and is given in good faith, but because of factors which are outside our knowledge and control and effect the use of products, no warranty is given or is to be implied with respect to such information. Specifications are subject to change without notice. Statements of operating limits quoted in this publication are not an indication that these values can be applied simultaneously

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James Walker Iberica SAT: +34 94 4470099F: +34 94 4471077E: iberica@jameswalker.biz

James Walker Ireland LtdT: +353 (0) 21 432 3626F: +353 (0) 21 432 3623E: sales.ie@jameswalker.biz

James Walker Italiana srlT: +39 02 257 8308F: +39 02 263 00487E: jameswalker@jameswalker.it

James Walker Mfg Co (USA)T: +1 708 754 4020F: +1 708 754 4058E: sales.jwmfg.us@jameswalker.biz

James Walker MoorflexT: +44 (0)1274 562211F: +44 (0)1274 566623E: sales.moorflex.uk@jameswalker.biz

James Walker New Zealand LimitedT: +64 (0) 9 272 1599F: +64 (0) 9 272 3061E: sales@jameswalker.co.nz

James Walker Norge AST: +47 22 706800F: +47 22 706801E: firmapost@jameswalker.no

James Walker RotaBoltT: +44 (0)1384 214442F: +44 (0)1384 455186E: sales@rotabolt.co.uk

James Walker Singapore Pte LtdT: +65 6777 9896F: +65 6777 6102E: sales@jameswalker.com.sg

James Walker South Africa (PTY) LtdT: +27 (0) 31 205 6251/2/3F: +27 (0) 31 205 6266E: info.za@jameswalker.biz

James Walker Group companies