Tip of the Week

Three Tips to Control Leakage

ExxonMobil Technical Help Desk

In an attempt to manage costs, many companies that operate facilities that can have
high level of leakage incidents — particularly metalworking facilities and steel mills—
will opt for low-cost hydraulic fluids. However, this can create a “double whammy”
situation, causing companies to pay on two fronts: through increased oil consumption
rates and reduced equipment life.

So how can you prevent leaks from draining your bottom line? The following steps will
help you gain better maintenance control, yielding up to a 10 percent reduction in
lubricant consumption.

1. Track your systems:

Cataloging and labeling all major hydraulic systems can help accurately assess plant
wide capacity. By installing a metering device on lube storage tanks, you can measure
and record the gallons delivered on each fill.

2. Measure leakage:

After cataloging systems, establish a reasonable Hydraulic Fluid Index (HFI) baseline
that can be used to measure actual cost savings. You can use the equation below to
give you a consistent measure of leakage rates, independent of capacity, allowing you
to track performance as equipment set-up changes:

HFI= Annual Usage or Total Fluid Used

Reservoir Capacity Total Site Capacity

Using this calculation, pinpoint the reservoirs with leakage problems. The average
industrial plant has an annualized HFI of about 3:1, with the best plants averaging ratios
of 1:1.

3. Schedule Inspections and Continue Monitoring HFI:

Once the high-usage units have been identified, schedule ultraviolet/ultrasonic

inspections to identify the source of the leakage, which will help minimize the impact on
production until repairs can be scheduled. Continue to monitor HFI over time and
consider tracking “% capture”, an indicator of lubricant volume used versus volume
purchased. These efforts will help ensure you stay on target and reach your cost
savings objectives.

Three Tips to Control Leakage reprinted with permission of the Mobil SHC Club. All Rights Reserved.