It is estimated that more than 100 million gallons of lubricating oil could be saved annually by eliminating external leaks in pump systems, hydraulic machines, transmissions and oil pans. Approximately 70 to 80 percent of hydraulic fluid leaves a system due to leaks, spills, line and hose breaks, and installation errors. Research shows that the average plant uses four times more oil per year than its machines can actually hold, and this is not explained by frequent oil changes.
Leaks from seals and seals, pipe joints and gaskets, and damaged, cracked and corroded piping and vessels. The main causes of external leaks are improper selection, improper application, improper installation and improper maintenance of sealing systems. Other causes include overfilling, pressure from clogged vents, worn seals and overtightened gaskets. The main causes of initial seal failure and fluid leakage are cost cutting by machine design engineers, incomplete plant commissioning and start-up procedures, and inadequate equipment monitoring and maintenance practices.
If a seal fails and causes fluid to leak, purchasing poor quality or incorrect seals, or careless installation when replacing, the problem may persist. Subsequent leaks, although not considered excessive, may be permanent. Plant operations and maintenance personnel soon determined that the leak was normal.
Leak detection can be accomplished by visual inspection, which can be assisted by the use of dye or replenishment of oil records. Containment can be achieved using absorbent pads, pads and rolls; flexible tubular socks; partitions; needle-punched polypropylene fibers; loose granular material from corn or peat; trays and drain covers.
Failure to pay attention to some basic details costs millions of dollars each year in fueling, cleaning, external liquid waste disposal, unnecessary maintenance downtime, safety and environmental damage.
Is it possible to stop external fluid leaks? The correctability rate is assumed to be 75%. Mechanical design engineers and service personnel need to pay greater attention to the proper selection and application of seals and sealing materials.
When designing machines and selecting suitable sealing materials, design engineers may sometimes select unsuitable sealing materials, primarily because they underestimate the temperature range in which the machine may ultimately operate. From a design perspective, this can be a major cause of seal failure.
From a maintenance perspective, many maintenance managers and purchasing agents decide to replace seals for the wrong reasons. In other words, they prioritize seal replacement costs over seal performance or fluid compatibility.
To make more informed seal selection decisions, maintenance personnel, design engineers, and procurement professionals should become more familiar with the types of materials used in oil seal manufacturing and where those materials can be used most effectively.
Post time: Nov-09-2023