"This is the most reliable and trustworthy company I have ever worked with. No surprises, no disappointments, they walk the walk and talk the talk. They are men of their word."
Independent Sealing Distributor
Some of our success stories:
Power Generation
Fisher Control Valve - Losing over $11,000/yr in steam and had to be repacked at least ever four months.
Paper Mill
These Hydro Water Wheels have been leaking since they were installed at the turn of the century.
Power Generation
Over 3 years of leak-free service for 325 steam valves repacked by FSS
Power Generation
Bad asbestos packing removal experience turned sweet
Hydro Generation
Stubborn wicket gate packing would come out
Power Generation
Clinker grinders had to be repack 8 times a year, FSS cut it to once every two years
Fertilizer Plant
Static electricity in the air would ignite these butterfly valves on a 2200 psi Ammonia and Hydrogen gas line, nobody but FSS could solve the problem.
Food Processing Plant
Took four men 5 weeks to extract the packing out of their food processing equipment. FSS sent two men and completed the job in 4 days.
Office Building
Annual steam loss of $12,750.00 through valve stem leakage was stopped over the weekend.
Hospital
Because of the surgery room demands for steam very early in the morning, and a shortage of maintenance workers, there was no way the loss of steam from the main headers could be stopped.
Paper Mill
Unscheduled outage, so much to do and so little time.
POWER GENERATION
Fisher Control Valve -
$12,383.92 Savings
Doesn’t seem possible that a steam leak could cost you that much. This 400# steam Fisher Control Valve leaked 700 lbs. of steam an hour and at $3.50/1000 pds, that’s $11,466.00 annually.
Valve was packed with a wire-inserted high temperature packing and had to be changed out at least three times a year at a cost of $576.63. Now add the steam loss to this and you are now up to $12,042.63.
Fluid Sealing Service recommended their live-load sealing system with a 100% Performance Guarantee. Materials were $185.29 and labor to repack was $156.00, total cost was $341.29. Valve has been in leak-free operation for 23 months now.
Hydo Water Wheels installed at the turn of century when this paper mill was built had a long history of leakage problems. The large shaft diameter equipment had eccentricity problems, leakage was by the bucket fulls.
The past five years the equipment was packed with a Garlock Braided Graphite Impregnated PTFE with a rubber hollow core at a cost of $1,185.00 per machine. Despite maintenance’s efforts, packing would leak on start-up.
Fluid Sealing Service recommended their GFM Sealing System at a cost of $1,391.00 installed. No leakage on start-up, the equipment has been running leak-free for over 12 months.
PAPER MILL
Century Old Leakage
Problem Solved
POWER GENERATION
Asbestos Packing Removal At Substantial Savings
HYDRO GENERATION
Can’t Get Packing Out Of Wicket Gate Stuffing Boxes
POWER GENERATION
Clinker Grinder – Savings of $2,400
FERTILIZER PLANT
$16,578.00 Minimum Annual Savings
FOOD PROCESSING PLANT
$12,940.00 Labor and Material Savings
OFFICE BUILDING
Return-On-Investment 67 days
A purchasing agent walking through the boiler room at the corporate headquarters of a leading financial business noticed visible steam leakage from a number of valves. Wondering if that steam loss was costing the company money, he asked the maintenance superintendent if he could determine what it costs to produce steam.
The maintenance superintendent contacted FSS. In just a few days FSS presented the results of the Leak Survey Analysis, which identified a total of 42 leaking valves at an annual cost of $12,750.00.
In one weekend, FSS extracted and repacked all valves with no interruption to the office buildings heating capabilities at a total cost of $2,350.00. Return-On-Investment was 67 days. Not a chill was felt by anyone.
HOSPITAL
Return-On-Investment 3 days
The maintenance supervisor at this hospital knew that the main header valves on his boilers were all leaking steam costing the hospital thousands of dollars and also presented a safety hazard for anyone who strayed near them. His problem was that his staff couldn't take the boilers down long enough to repair the leakage because food service and surgery needed steam in the early morning hours.
FSS was asked if there was anyway they could repair the leaks without interrupting steam service. FSS technicians found the valves were costing the hospital in excess of $10,000.00 per year. A plan was developed where FSS would work weekend nights with steam available for foodservice and surgery early each morning. Because of pre-planning and train certified valve service technicians, the repack project was completed in only one weekend, under budget and guaranteed leak-free for 5 years. Return-On-Investment was 3 days. Surgery went on as planned and no one went hungry that weekend.
PAPER MILL
Unscheduled Outage
This maintenance superintendent was just informed that in less than 30 days the #8 boiler was coming down for an unplanned 3 day shutdown. The superintendent had a lot of planning, estimating and scheduling to do in a short period of time. There were a lot of valves to repack and not enough manpower to complete it.
One call to FSS brought a quick response. In days FSS was onsite and the superintendent was presented with a comprehensive Valve Leakage Analysis Summary that identified the valves to be repacked, predicted both in-house and contractor man-hours required, cost of all packing materials, timeline, detailed work orders for all 198 valves, all at a firm price.
With one call, the superintendent had completed his planning, estimating and scheduling for the entire repack project. He also had confidence that the repack project would go according to plan, giving him more time to supervise more important projects during the outage. One call did it all.
Stuffing boxes were saturated with hardened food product making the removal of packing a very long and messy project. To clean all stuffing boxes and repack them, it took four maintenance men 5 weeks to complete the job at a cost in excess of $16,000.00.
Fluid Sealing Service sent a two man crew with a water-jet and extracted and repacked all the equipment in 4 days at a total cost of $3,060.00 2200 psi Ammonia and Hydrogen gas line has a series of 12 butterfly control valves that had a history of leakage problems. Static electricity in the air would ignite the leaking product, resulting in 3 to 4 fire hoses hours to put out the fire.
In the last four years, four different packing manufacturers and their distributors were given a chance to provide sealing systems to eliminate leakage. On average, all sealing systems failed within 6 weeks.
Fluid Sealing Service was contacted to provide a solution to the problem. After investigating previous efforts, valve design, and pressure changes, FSS recommended their turn-key HP Engineered Sealing System at a cost of $7,022.00 and guaranteed it leak-free. Result – No leaks – No fires – Leak-free operation from one shutdown to the next.
Previous year’s cost for 8 occurrences, $23,600.00 plus fire fighting costs. Anybody that looks at a stuffing box on a clinker grinder knows how hard they are to pack. This power plant was spending a lot of money to repack their clinker grinders about 8 times a year. They tried most major packing manufactures products, the most previous was Chesterton Style 1727.
Fluid Sealing Service recommended their GFM Engineered Sealing System at a cost of $2,040 for four Clinker Grinder units. This sealing systems has operated leak-free for the past 14 months.
According to plant records, they spent in excess of $4,440.00 the previous year in packing materials and repacking costs. Leaking water from these wicket gate stuffing boxes was so bad the plant had four sump pumps trying to keep up. When the #2 Unit came down for maintenance, one of the top priorities was to repack all 24 stuffing boxes.
A 3 man crew work for two days and only removed a ring and half from one stuffing box. Years ago someone had installed the wrong style of packing. It was a high temperature inconel wire insert steam packing that had been compressed very tightly from over tightening the gland follower. This packing was rock hard and you would bend a pick trying to dislodge it.
Fluid Sealing Service sent one technician and a ultra high pressure water-jet to remove the packings. In two days he had extracted and cleaned out all 24 stuffing boxes and had repacked them with the correct style of packing. On Monday morning, the maintenance crew was pleasantly surprised to see the project was completely finished. This mid-west power plant had a bad experience with a company hired to extract ACM packings and repack valves at their plant. Problems ranged from poor project planning, not licensed to remove asbestos, not enough man power, not completing the project, and excessive additional costs.
You can imagine why these guys were on edge when we quoted this project to be completed in half the time at almost half the costs. They checked our reference's out and gave us the job. FSS completed the project on time and below estimated project costs.POWER GENERATION
Thirty-Six Months Of Leak-Free Service For Over 300 Valves
This coal-fired power generation plant was going into its first thirty-six month turn-around and had concerns about valve stem leakage during this extended period. They sought vendor recommendations and proposals for turn-key repack service and sealing systems for over 300 valves that would provide the benefits they were looking for.
Of all the vendor proposals, there was only one vendor that provided the benefits and assurances they were looking for.
Fluid Sealing Service proposed their VPOS (Valve Packing Optimization System), which provided a turn-key valve repack with a firm-hard price in addition to a Five Year Leak-Free Warranty. This complete valve repack system turned this worry-some project into a worry-free valve repack process from evaluation to system start-up.
