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07.17.2023

Parker Dry Technology: Don't Let Leakage Harm Your Profits

DID YOU KNOW? UNDETECTED AND UNTREATED HYDRAULIC CONNECTION LEAKAGE CAN INCREASE COSTS BY MORE THAN $2,000 PER YEAR

 

In addition, hydraulic connection leakage can create hidden costs such as:

  • Energy loss

  • Safety hazards

  • Environmental responsibilities

  • Maintenance costs

  • Lost sales

  • Warranty

 

To minimize hydraulic leakage and its resulting costs, Parker created the Dry Technology methodology that identifies the major causes of leakage and provides tips to prevent them. 

 

visual outlining oil leakage per drop, over 24 hours resulting in over $2,000 loss per year

1 drop every 1 minute = 6.7 gallons per year = $33.50

1 drop every 10 second = 40 gallons per year = $200.00

1 drop every 5 second = 80 gallons per year = $400.00

1 drop every second = 402 gallons per year = $2,010.00

 


 

MAJOR CAUSES OF LEAKAGE & TIPS TO AVOID THEM

 

60% OF ALL LEAKAGE COMES FROM IMPROPER INSTALLATION

COMMON INSTALLATION PROBLEMS INCLUDE:

  • Over-tightening or under-tightening fittings.

  • Different thermal expression properties, temperature fluctuations cause intermittent leakage in tapered thread connections.

  • Removing too much material when deburring tube ends.

  • Forcing or “drawing in” tube assembly that is too short, long, or misaligned.

  • Improper routing of lines.

  • Removing protective plastic caps during installation (causes thread damage and contamination).

 

DRY TECH TIP: MOST HYDRAULIC LEAKS AT INITIAL STARTUP ARE CAUSED BY JOINTS THAT WERE NOT TIGHTENED PROPERLY AND ARE NOW TOO BURIED FOR EASY ACCESS.

 


 

20% OF ALL LEAKAGE COMES FROM POOR SYSTEM DESIGN

Selecting the right components to fit the application is a critical first phase in preventing leakage.

APPLICATIONS THAT MUST BE CONSIDERED INCLUDE:

  • ENVIRONMENT - Where is the system operating and how will that affect its performance? Is it in an environment where it will experience excessive corrosive or mechanical abuse?

  • PRESSURE - What is the minimum + maximum pressure? What is the number of times the pressure will cycle between those two pressure points?

  • VIBRATION - How severe is the vibration? Will the vibration cause the components to loosen or prematurely fail?

  • SHOCK - Will the component be subjected to mechanical or hydraulic shocks that could be detrimental to its expected life?

  • CONTAMINATION - Is the style and quality selected introducing contaminants into the system?

  • FLUID VELOCITIES - Does the tube and fitting size allow for acceptable velocity?

  • AMBIENT & FLUID TEMPERATURE - What extreme temperatures will the machine be exposed to and how will they affect the material in the components?

 

DRY TECH TIP: COMPUTER SOFTWARE CAN GREATLY EXPEDITE OTHERWISE LABOR-INTENSIVE CALCULATIONS SUCH AS PRESSURE DROP.

 


 

15% OF ALL LEAKAGE COMES FROM POOR QUALITY COMPONENTS

WHEN DETERMINING WHICH PRODUCTS WILL BE BEST FOR YOUR SYSTEM'S REQUIREMENTS, CHOOSE HIGH QUALITY COMPONENTS:

  • Fittings with elastomer seals are the most reliable but it is important to check temperature limitations.

  • A higher hardness forging is not necessarily better. Brittle failures can occur with harder materials.

  • Due to weight considerations, titanium tube is often required in aerospace/aircraft applications.

  • Thicker tubing is often used to create a more rugged system.

  • Adjustable straight threads are more reliable than pipe threads on shaped fittings.

 

DRY TECH TIP: FACE SEAL O-RINGS SHOULD ALWAYS BE INSTALLED WITH AN INSERTION TOOL TO PREVENT THEM FROM TWISTING OR POPPING OUT.

 


 

5% OF ALL LEAKAGE COMES FROM SYSTEM ABUSE

System abuse is often assumed to be a user-end issue that simply can’t be stopped, but it can be controlled.

FOLLOW THESE IMPORTANT STEPS BEFORE PUTTING THE ASSET INTO THE END-USER’S HANDS:

  • Make available enough space (wrench clearances) to maintain equipment properly.

  • Provide key specialty tools (e.g., captive O-ring insertion tools) that the user would normally not have access.

  • Use maintenance manuals that provide not just OEM and manufacturer part numbers, but proper assembly techniques for servicing.

  • Utilize protective caps and plugs for threaded connections, and don’t remove them until the final connection with the mating tube and hose assembly is made.

  • Include routing designed to reduce the possibility of the user standing or climbing on the plumbing.

 

DRY TECH TIP: WHILE ELASTOMER PORT SEALING METHODS ARE TYPICALLY PREFERRED, THEY MAY HAVE TEMPERATURE LIMITATIONS. FOR THIS REASON, METALLIC PORT SEALING MAY BE PREFERRED.

 


 

Finally, when selecting hydraulic connectors, it is important to understand:

  • How to select the proper fitting for your system using the S.T.A.M.P method

  • Tube/hose end selection

  • Port selection

  • Selecting hydraulic tube

  • Proper tube and fitting assembly

  • Bending, routing and clamping

  • How to troubleshoot typical connection leakage problems 

 

DRY TECH TIP: A WELL-DESIGNED SYSTEM IS ONE THAT TAKES EASE OF MAINTENANCE INTO CONSIDERATION ALONG WITH PROPER FUNCTION AND EASE OF INSTALLATION.

 

To learn more, download the Parker Dry Technology Guide to Leak-Free Connections! Or to speak with an MCE expert or to request dry technology training for your facility, contact us today!

 

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