Pop Washer™ Case Study

A refinery owner needed a safer, faster, and better method to breakout their critical path DCU flanges. The DCU cycled from 150°F to 900°F every 18 hours and breakout had traditionally been a dangerous and dreaded challenge. Operators had to rely on torches and nut splitters to remove seized nuts every breakout.

They made the choice to install the Pop-Washer™ and here’s how their breakouts changed:


1,000,000+ hours of combined total usage 500+ activations

  • All nuts were spun off by hand
  • Entire disassembly took 88 minutes
  • 78% reduction in breakout time
  • All hardware was left in good condition


  • 75% of the studs had to be burnt off
  • Up to 1/2 shift of delays
  • Hot work permits were required
  • New hardware was purchased every breakout