All leakage issues were eliminated due to these additions. As there are no leaks, there is no release of hydrocarbon vapours, which drastically reduced severe hazards. Therefore no hot torquing was required, no loss of process vapour occurred and no downtime was experienced. Costs have dramatically reduced and safety has dramatically improved.
In the long term, the savings are significant. Previously the customer had nine unscheduled shutdowns, but in the past six years, with the Chesterton solution, the customer is confident that this equipment can run for up to 75 months without any concerns.
Pleased with the results Chesterton provided, the customer decided to upgrade all other heat exchanger units to the Chesterton Live Loading.
One leak requires complete disassembly of the bundle, overhaul of the flange, replacement of the gasket, bolts and nuts, and a complete reassemble at MYR 50,000 per event (approx. 17,000 AUD).
Previous total leaks:
Nine times in six years = MYR 450,000 (approx. 150,000 AUD)
The Chesterton-provided solution cost MYR 50,000 (approx. 17,000 AUD) one time with a service life of 6.26 years.
Total saving of approx. MYR 400,000 (approx. 135,000 AUD) over 6 years, or MYR 67,000 per year (approx. 23,000 AUD).