The value of leak testing in preventing hydraulic fluid leaks NFPA - - PowerPoint PPT Presentation

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NFPA Milwaukee Regional Meeting Milwaukee School Of Engineering (MSOE) September 27, 2016

Thomas Braun, VP Product Development Fastest Incorporated

The value of leak testing in preventing hydraulic fluid leaks

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2015 NFPA Technology Roadmap 6 broad areas of “challenge”

• Increasing the energy efficiency of fluid power components and systems
• Improving the reliability of fluid power components and systems
• Reducing the size of fluid power components and systems while

maintaining or increasing their power output (higher working pressure)

• Building “smart” fluid power components and systems (i.e. ones that

perform self‐diagnostics)

• Reducing the environmental impact of fluid power components

and systems (e.g., lowering noise, eliminating leaks)

• Improving and applying the energy storage capabilities of fluid power

components and systems

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It’s an Environmental Issue…

• It is estimated that 700 million gallons (2.65 billion liters)
• f petroleum products enter the environment each year 1
• The hydraulic contribution is estimated to be 98 million

gallons (370 million liters) 2

– This represents the amount of oil leaks from/out of hydraulic equipment each year!

1 National Oceanic & Atmospheric Association (NOAA) 2 Gates Corporation

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It’s an Economical Issue…

• “Little Leaks” can easily cost <$2000/year/leak point 1

– Make-up oil

• A 0.5cc/min leak = 263 liters/year @ $3/liter = $789

– Clean-up

• $20/week for labor & consumables = $1000

– Disposal

• @ $1/liter disposal cost x 263 liters = $263

– Contaminant ingression

• Causes component damage ($)
• Fluid degradation ($)
• Downtime from reliability problems ($)

– Safety “intangibles”

1 Brendan Casey: How little leaks keep hydraulic equipment users poor

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Unfortunately, it’s also a Performance Issue…

• Internal system leaks also affect equipment performance

– Slow operation = loss of efficiency – Increased hysteresis – Cylinder drift – Etc.

• And they drive operators crazy!!!

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In short, “leak-free” is critical to trouble-free

• peration… and becoming more so all the time!
• Fluid Power OEM’s are demanding more and more that

new & remanufactured components be certified to meet leakage (internal & external) specifications

• Suppliers are using post assembly leak testing to verify

the performance of new or remanufactured components

– These components include…

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NFPA

Pumps & Motors Hose Assy’s Manifolds Valves Cylinders Fittings

NFPA Component Suppliers Require Leak Free!

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NFPA Agriculture: Tractors Windrowers Combines Industrial: Sweepers Automation Marine: Ships Pleasure boats Wave runners Construction: Excavators Loaders Skid steers Dozers Cranes

NFPA Equipment Customers do too!

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What are the common leak test methods?

• Common methods

– Water immersion – Bubble – Pressure decay – Helium leak – Etc.

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• Regardless of the leak test method used the objective is

to perform the test in the shortest time possible with accurate results

• Often times a Fitting is used to connect to a threaded

port of a hydraulic/pneumatic component

• Common interface’s include:

– Threads (Female or male)

• Taper (NPT & BSPT)
• Straight

– O-Ring Boss (ORB)

– Fittings (JIC 37° Flare, ORFS, other compression)

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• A critical consideration is achieving a leak free seal to

the component being tested.

• Common practice today is to screw & torque a fitting or

QD into the component port. This is inefficient (slow/time consuming) and can yield inconsistent results. In addition it can “damage” a new component (cylinder, pump, valve, etc.) just to test it!

Screw in fitting for test

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• Top-Tip:

Use a proper Quick Test Connector!

– A tool designed for the job, i.e. repetitive, quick, leak free and non-damaging connections

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• Top-Tip:

Use a proper Quick Test Connector!

– A tool designed for the job, i.e. repetitive, quick, leak free and non-damaging connections

www.fastestinc.com

• Top-Tip:

Use a proper Quick Test Connector!

– A tool designed for the job, i.e. repetitive, quick, leak free and non-damaging connections

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• Feature

– Quick connect design – Damage-free connect – Pressure assisted internal compensation – Torque-free connect – Multiple configurations – Made in USA

• Benefits

– Saves time/pays for itself quickly – Test does not harm component being tested – The higher the pressure the better it seals – Relieves fatigue & injury – Sizes & Styles for most threads, fittings & tubes – Local, fast supply & service, local distributors

Quick Test Connectors… Fast - Reliable - Safer

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• In Summary

– Leaks are leading cause of lost performance

• They are associated with many obvious and hidden costs ($$$)

– Leaks are environmentally harmful – OEM’s and End-Users are demanding leak-free components – Component testing is common and a growing trend for Tier 1 & 2 suppliers and with remanufacturers and servicers – A reliable connection during a leak test is critical – Common fittings are slow to install/remove for a test, can cause damage, can contaminate the system and require torqueing which can lead to worker fatigue & long term injury – Using proper Quick Test Connectors can save time, seal reliably, eliminate contamination, reduce fatigue, long term injuries and workman’s comp claims/insurance premiums!

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Th Thank ank you u for r your ur atte ttention! ntion!

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