As regulatory requirements tighten and end users demand higher environmental performance, fugitive emissions control has become a critical differentiator for ball valve manufacturers. One such manufacturer, previously relying on standard sealing solutions, sought to upgrade its valve performance to meet the expectations of a more demanding customer base and achieve dual fugitive emissions qualification.

However, the existing valve seals were not capable of meeting the required emissions and pressure performance benchmarks. This limitation restricted the manufacturer’s market access and reduced its ability to compete in applications where low-emission certification is mandatory.

The Challenge: Upgrading Performance Without Redesigning the Valve

Achieving fugitive emissions compliance often requires significant design changes, such as modifying the valve body or stem assembly. In this case, the customer faced several constraints, including existing hardware geometry, operating pressures, temperature ranges, and the need to maintain production efficiency.

Rather than recommending a complete valve redesign, JST worked in close collaboration with the customer to evaluate the valve’s hardware configuration, operating conditions, and performance limitations. The objective was clear: develop an upgraded valve sealing solution capable of meeting fugitive emissions standards while preserving the original valve architecture as much as possible.

The Engineering Approach

To address these challenges, JST implemented a structured development process focused on targeted sealing improvements rather than wholesale design changes:

1. Design Assessment

A comprehensive review of the existing ball valve design was conducted to identify the root causes of emission leakage and pressure performance limitations.

2. Innovative Sealing Configuration

An optimized sealing arrangement was engineered to balance pressure retention and fugitive emissions control, ensuring reliable sealing under both static and dynamic conditions.

3. Advanced Material Selection

High-performance sealing materials were selected for their ability to operate reliably across a broad temperature range while maintaining low permeability and long-term durability.

4. Hardware Compatibility and Manufacturability

The final design was refined to integrate seamlessly with the existing valve hardware, minimizing required modifications and maintaining production efficiency.

Throughout the development process, close communication with the customer ensured that performance targets, certification requirements, and manufacturing considerations were fully aligned.

The Result: Proven Fugitive Emissions Compliance

Thanks to JST’s sealing expertise and application-driven engineering approach, the customer successfully achieved the targeted fugitive emissions performance through laboratory qualification testing.

The project delivered measurable benefits:

Improved valve performance and long-term reliability under demanding operating conditions

Compliance with critical fugitive emissions standards, enabling access to new customer segments and regulated markets

Confidence in field performance, supported by successful laboratory validation and qualification testing

A Targeted Approach to Valve Seal Upgrades

This project highlights the value of enhancing critical components—such as valve seals—rather than pursuing costly and time-consuming valve redesigns. By focusing on sealing configuration, material performance, and compatibility with existing hardware, JST enabled the customer to achieve low-emission certification while preserving their original valve design and manufacturing processes.

For ball valve manufacturers facing similar challenges, a targeted valve sealing upgrade can be a highly effective path to fugitive emissions compliance, improved product differentiation, and expanded market opportunities.