Gaskets Case Study: Live Loading on Heat Exchanger
SJP case study APAC0006 – Chesterton products – Chesterton Gaskets
Chesterton carries specially-designed, high-strength springs that deliver a reserve of elastic energy to each bolt, allowing them to maintain a constant load on the flange and gasket during normal operation. They have the ability to provide dramatic improvements in leakage performance and service life.
Products featured in the case study:
- Chesterton® 5505H Live Loading Spring
A Malaysian bitumen plant faced frequent hydrocarbon leaks from the shell and the tube heat exchangers throughout the plant. Leaking Hydrocarbon is a severe hazard both to equipment and to the safety of plant personnel as the 300°C vapours represent a high fire risk.
Lance tubes and hot torquing are both utilized in this plant to reduce safety concerns and production loss, which also results in high-end product and maintenance cost losses.
The customer’s focus is to improve the reliability of the plant, reducing the risk of fire hazards and most importantly, safeguarding the health of workers.
The solution was the installation of Chesterton® 5505H Live Loading Springs, a new Kammprofile gasket, 725 anti-seize and new mechanic nuts and bolts. Installed in May 2015, these alterations ensured no leakage events through start-up and production cyclic processes.
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).
Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service.
Mentioned in the case study:
SJP Sealing Technology (S) Pte Ltd
Exclusive Distributor of Chesterton products – Singapore & Malaysia
® Registered trademark owned by A.W. Chesterton Company
Case Number APAC0006 – Issued 08/20