2 R134a Turbocor chillers on the same site, circa 6 years old:

Where the discharge and liquid pipe headers connect onto the aluminium heat exchangers, each fitting/union comprises of 2 x o-rings to effect the gas tight seal. A total of 36 joints (72 o-rings) per chiller - almost every one of them is leaking (badly).

I'm thinking poor pipework alignment at the factory, poor aluminium H/E tolerances or perhaps lack of care during transportation and/or lifting/installation.

Any my experience or insight to this issue hugely appreciated.

As always, thanks to anyone who takes the time to read this plea!

LAF