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Reducing hazardous work risk in coking plant

Challenge

In a coking plant, the bolts holding the beam that expelled the coke came loose. Due to this, weekly inspections and retightening was necessary. Inside the coke oven, temperatures reach up to 1100 degrees Celsius. It has also been noted that a stable torque had not been applied properly. The goal is to eliminate the loose bolt and reduce constant retightening; this in turn will reduce the hazardous work risk.

Coking Plant- Steel Mill

Solution

Chesterton specialists identified that there were no gaskets installed. The following products were used:

Chesterton specialists supplied the customer with eight pieces of the Chesterton’s 5505H Flange Disc Springs.

  • Specially-designed, high-strength springs.
  • Deliver a reserve of elastic energy to each bolt, allowing them to maintain a constant load on the flange and the new gasket during normal operation or thermal cycles.
  •  Improve leakage performance and service life. 

Chesterton’s 5505H Flange Disc Springs

The Chesterton 783 ACR: Corrosion-Resistant Anti-Seize was also applied.

  • Metal-free, high-performance industrial anti-seize.
  • Extreme corrosion protection and water washout resistance.
  • Ideal where the corrosion is of concern.
  • Provides excellent protection of metal components under extreme conditions.

Chesterton 783 ACR: Corrosion-Resistant Anti-Seize

Results

The Chesterton solutions were applied in June 2018, with more than 1000 pieces  being delivered as of March 2021. No loosening of bolts or retightening has been reported.

ROI
Before Chesterton Solution Annual costs: ¥3,600,000

(2 hours labour x 2 people each month) – Approx. USD
26,000

2018 – Chesterton 5505H cost approx. ¥2,900,000 –
Approx. USD 21,000

Cost reduction of ¥700,000 difference in the first year
alone. Approx. USD 5,000

Succeeded in reducing rework by 192 hours annually

About us

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. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.

® Registered trademark owned by A.W. Chesterton Company

APAC0060.  Issued 01/2023.

Technical data reflects results of laboratory tests and is intended to indicate general characteristics only. A.W. Chesterton Company disclaims all warranties expressed or implied, including warranties of merchantability and fitness for a particular purpose. Liability, if any, is limited to product replacement only. Any images contained herein are for general illustrative or aesthetic purposes only and are not intended to convey any instructional, safety, handling, or usage information or advice respecting any product or equipment. Please refer to relevant Safety Data Sheets, Product Data Sheets, and/or Product Labels for safe use, storage, handling, and disposal of products, or consult with your local Chesterton sales representative

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