Field Engineer Thomas Olsen on Leakage
Thomas Punsvik Olsen, field engineer based in Stavanger with over 7 years at Swagelok Norway, has vast experience locating and finding solutions for leakage in customers’ systems. Typically, with the help of his analysis and recommendations, customers are able to save tens of thousands of kronor per year while also reducing the potential for environmental and safety hazards.
What are the most common causes of leakage you observe in customer systems?
The most common cause of leakage I see in the field is absolutely mistakes made during installation. Components are over- or under tightened, tubing isn’t deburred properly, there aren’t enough supports used to mount tubing, or the minimal bend radius is incorrect. I see a lot of leakage due to intermix, the use of tube fittings from different manufacturers, as well. Sometimes customers see it as a way to achieve short-term savings, but it isn’t worth it in the long run.
Some leakage can be traced all the way back to the design phase when a component not designed for its intended use, not made with the right materials, or without the service life potential for the design is mistakenly specified.
How can leakage be prevented?
There are plenty of things that can be done to prevent leakage. First, specify the right components from the beginning. If you’re unsure, my colleagues and I are happy to help. The initial purchase of high-quality components can often prove to be the smallest piece of the total cost of ownership. When using products of a lower standard, the cost of lost media and production efficiency due to leakage, along with the cost of repairs and replacements, will be higher. High-quality components are also going to help and make sure nothing hazardous leaks into the atmosphere, keeping associates safe and the environment clean.
Another step that can be taken early on is to simplify the design so that it’s service-friendly or even choose customized, fully fabricated system assemblies.
I’d also recommend being proactive by keeping an inventory of spare parts on-site, and by taking regular advantage of leak detection services.
The very best thing that can be done to prevent leakage, though, is to make sure that service personnel are trained to use a gap inspection gauge, deburr tubing to prevent particles in the system, and avoid over- or under-tightening, among other skills. Investing in 1 - 3 days of training for installers can save untold money and time in the future, as well as ensure associate safety and environmental compliance.
What can be done once leaks are identified?
Remember that if leaks are a common occurrence in your facility, you are not alone. I find leaks in most plants I visit, and they can be a major drain on plant efficiency, but I appreciate that it may not be possible to resolve every leak all at once. That’s why after each system analysis my team of field engineers and I deliver a prioritized list based on which leaks are costing the most money and are risks to health, safety, and the environment, as well as specific recommendations for resolving them.
Learn more here:
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