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Power Points, the Online Newsletter
Loctite: Lost Profit Found!
Leakage is the source of millions of dollars in lost revenues that occur daily in various industries. Different applications require different forms of media used in the processing operation. Examples of various types used are:petroleum based hydraulic oils, synthetic fluids, steam and compressed air. Each different medium loss carries a different value. Depending upon leak severity and regularity, those annoying little droplets can add up to a profound impact on your bottom line profitability.
Leak Cost Calculation Data
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| Petroleum Based Hydraulics and Oils |
|
STANDARD |
| LEAK SEVERITY |
LEVEL |
GALLON LOSS PER YEAR |
LEAK COST PER YEAR |
| 1 drop/10 seconds |
A |
39.6 |
$ 257.40 |
| 1 drop/5 seconds |
B |
79.2 |
$ 514.80 |
1 drop/
second |
C |
409.2 |
$2659.80 |
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| Synthetic Hydraulic Fluid |
| LEAK SEVERITY |
LEVEL |
GALLON LOSS PER YEAR |
LEAK COST PER YEAR |
| 1 drop/10 seconds |
A |
39.6 |
$ 356.40 |
| 1 drop/5 seconds |
B |
79.2 |
$ 712.20 |
1 drop/
second |
C |
409.2 |
$3682.50 |
|
| Steam (at 100 PSIG) |
| LEAK SEVERITY |
LEVEL |
GALLON LOSS PER YEAR |
LEAK COST PER YEAR |
| 1/64" Orifice |
A |
1.6M |
$ 15.20 |
| 1/32" Orifice |
B |
6.3M |
$ 59.85 |
|
| Compressed Air (at 100 PSIG) |
| LEAK SEVERITY |
LEVEL |
GALLON LOSS PER YEAR |
LEAK COST PER YEAR |
| 1/64" Orifice |
A |
129M |
$ 38.70 |
| 1/32" Orifice |
B |
516M |
$ 154.80 |
As the "Leak Cost Calculation" data sheet illustrates, a tiny one drop per second of synthetic hydraulic fluid, could result in a $3700 leak cost per year. The use of Loctite sealants can be a way to help prevent leakage and fluid loss. Loctite anaerobic pipe thread sealants can be used on metal fittings and help prevent leakage caused by vibration loosening, tape shredding, solvent evaporation, and temperature cycling. Other gasketing and sealing products are also available from Loctite. Feel free to contact any one of our sales offices for more information. Let Power Industries and Loctite "team up" to help stop leakage costs!
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Power Points, the Online Newsletter
Bearing Maintenance
To insure normal bearing life it is necessary to have a proactive
preventative maintenance program. A good program contains these five practices:
- Develop a systematic checking and servicing program for your bearings.
- Recognize the warning signs of potential bearing failure---overheating,
noise, and vibration.
- Recognize the various types of damage and determine possible causes.
- Take steps to correct the problem to prevent it from happening again.
- Check to make sure the problem is eliminated.
Following is a list of some key maintenance considerations that if ignored
may lead to potential premature bearing failure.
- Normal Conditions---Bearing should be approximately 1/2 to 2/3 filled with
grease. Lubricate per schedule in instruction manual---from once per shift
to once per year depending on rpm, load, etc.
- Dirt and Abrasives---Keep bearing as full of lubricant as possible.
Lubricate frequently to purge contaminated grease from the bearing and
seals. Never allow dirt and abrasives to pack solidly around the bearing.
Where possible provide deflectors to protect bearing from falling dirt or
water.
- Moisture---Lubricate at frequent intervals with lithium base grease or
other suitable moisture resistant grease. Do not use soda base grease on
extremely wet applications.
- Corrosives---Frequent lubrication is essential to purge any contaminated
grease form the bearing. Also, consult lubricant manufacturers for
suggestions on special additives in the grease to protect against specific
corrosives.
- Heavy of Shock Loads---Extreme pressure (EP) type grease will help. Also,
a bearing housing that is made of ductile, malleable, or steel will help.
- High RPM---Consider oil mist lubrication, but grease can be used of it is
of heavy enough consistency to prevent "churning" in the bearing.
- High Temperature---A NO.2 consistency lithium based grease is provided and
is normally suitable for ambient temperatures up to 150F-250F (internal
bearing temperature 274F-300). For higher temperatures silicone grease may
be preferable and the derating of load capacity of the bearing may be
necessary.
- Vibration---Use extreme pressure (EP) greases and consider reducing
bearing clearances to retard "false brinnelling".
- Intermittent Service---Use a stable grease such as lithium grease. At the
end of a running season fill the bearing completely to protect against
moisture condensation. At start-up remove the grease fitting and allow
surplus lubricant to run out during initial running.
Finally, remember these five helpful hints:
- Grease does not last forever. Oil and base will separate when working. Oil
will oxidize and break down eventually. Contaminants become suspended in
grease therefore making it necessary to lubricate and re-lubricate.
- Never mix grease types! Adverse reaction can result. This can lead to the
mixture liquefying and oozing out of the bearing.
- Make sure grease fittings are accessible and cleaned before
re-lubricating.
- Use clean grease. Do not store grease in open containers.
- Make sure grease is getting into the bearing. If grease is oozing out at
the seal it is a good sight.
For further information regarding bearing maintenance please feel free to
contact any one of our sales offices.
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