Campbell Fittings Saves Refinery $1.5M Annually

In the high-stakes world of oil refineries, safety and cost-efficiency are paramount. A case study from Campbell Fittings highlights how our Crimped Steam Technology revolutionized operations at a U.S.-based oil refinery, leading to significant cost savings and enhanced safety. 

The Challenge 

During an inspection, over 100 steam hoses were found to be installed incorrectly or made of inferior materials, causing frequent leaks and increasing the risk of safety hazards. The leaks were particularly problematic, with each one costing the refinery approximately $1,250 per month. Additionally, many hoses lacked proper electrical continuity, which posed a danger of static discharge, potentially harming operators. 

The Solution 

Campbell Fittings, in collaboration with our distributor, recommended replacing the faulty hoses with our Crimped Steam Technology. This system features one-piece couplings and a metal-to-metal seal backed by a Viton™ O-Ring, eliminating leaks and the need for re-torquing bolt clamps. The crimped couplings also ensured electrical continuity, enhancing the overall safety of the refinery’s operations. 

The Results 

After installing 25 crimped steam hoses, the refinery experienced zero leaks during testing, leading to the rapid adoption of the technology. The transition resulted in verifiable savings of $1,250 per leak per month, culminating in an annual savings of $1.5 million. Additionally, the improved system reduced maintenance time and enhanced safety for refinery employees. 

Campbell Fittings’ Crimped Steam Technology not only solved the refinery’s issues but also set a new standard for operational efficiency and safety in the oil and gas industry. 

For more information on how Campbell Fittings can help you eliminate leaks, improve safety, and save money, please contact us!