Edmonton Valve & Fitting Blog

Any energy management program should include efforts to prevent and repair leaks

Leaks can be costly in more ways than one. Download our Hidden Costs of Leakage PDF to explore how a leak in your system could be impacting your business and budget. 

Leak breakdown

In any fluid system, there could be one or more kinds of leaks:

• Inboard leakage, where something is flowing into the system from outside
• Outboard leakage, where something is flowing out of containment into the environment, or
• Internal leakage, where something is flowing across internal seals within containment, such as a leaky valve seat

There can even be virtual leaks, where nothing is breaching the containment, but internally trapped fluid gets released into the system due to material out-gassing, absorbed or adsorbed fluids, entrapment in cracks or dead-legs, etc.

Leakage can take many forms, like:

• Compressed air leaking out of a pneumatic system
• Steam escaping from a processing line
• Hydraulic fluid seeping out of machinery

Common causes 

Bad installation techniques are frequent causes of leaks. Common mistakes include failing to fully insert tubing into the tube fitting body, under-tightening, over-tightening, putting bends in the tubing too close to the end of the tube, and poorly preparing the tube. Surface defects such as dents and scratches can lead to leaks too.

Another cause of leakage is using components outside their rated temperature and pressure ratings or with incompatible materials. Also, low quality fluid system components also contribute to leaks. Proper selection of high quality fluid system components are an integral part of creating leak tight fluid systems.

(Recommended: Get local help with product selection.)

Isn't some leakage normal?

It's true that whether it's an inboard, outboard, or virtual leak, no man-made system will always be leak-free. But consider the following:

A group of 1,304 different process installations leak checked more than 600,000 fittings for a five-year period ending in September 2013, and reported the results to Swagelok Company. Almost 10% of the fittings that had been interchanged or intermixed with another manufacturer's components were found leaking, and pipe fittings had a leak rate of about 7 percent. In contrast, Swagelok tube fittings had a leak rate of about 1%. (This data is not offered as test results that are scientifically valid or statistically significant.)

While the 1% leak rate for Swagelok fittings is 7-10 times better than pipe fittings and intermixed/interchanged fittings, we believe that one leak is one too many. So, we strive to get to the root cause of every leak. We find that many Swagelok tube fittings are not installed according to our installation instructions. Poor installation practices, low quality tubing, improper tubing or fitting selection - all these contribute to leak rates. We have found that customer leak rates can approach zero when Swagelok tube fittings are used in concert with high quality tubing, a robust Swagelok safety and installation training program, and energy management services.

Isn't tracking down and stopping all the leaks expensive?

Possibly -- but not stopping them is likely to be expensive too.

The leak data noted above correlates well with a study performed by Dr. Arthur Sterling of the Chemical The-Hidden-Costs-of-Leakage.png Engineering Department at Louisiana State University in 1999. Dr. Sterling surveyed eleven industrial plants in the Louisiana area and determined that leaks were present in many areas of the plant. The average instrument air leak was 494 milliliters per minute. Using a cost of $0.40 per 1000 cubic feet of instrument air, the average fitting leak costs $0.31 per month.

Leaks can damage equipment, hurt production, cause product contamination, and create unsafe working conditions and other health hazards. All it takes is a small puddle of hydraulic fluid or a jet of steam to put someone in the hospital.

If that is not motivation enough to engage in proactive leak detection and prevention programs, fluid loss is also expensive. According to a study conducted by the Energy Department's Office of Industrial Technologies, even something as simple as a ¼” diameter leak of compressed air can cost as much as $8,382 a year using a rate of five cents per kWh and assuming constant operation and an efficient compressor.

How to find leaks

We have a few ways to spot leaks. One is to put the suspect parts under water in a chamber made of transparent polycarbonate and look for bubbles. Another is to apply one of our Snoop® liquid leak detectors. When the parts are pressurized, the leak will produce bubbles. Leaks are usually expressed as a flow — a volume per unit of time. Anyone using Snoop will get the basic idea instantly: the bigger the bubbles, the worse the leak.

Leaks can also be detected by measuring losses in pressure, and of course by simply looking to see if any fluid is escaping. Technology has added to the arsenal of tools. The list now includes thermal imaging cameras and ultrasonic (acoustic) leak detectors.

Leak detection + leak prevention = better safety and lower costs

Any good energy management program should include efforts to prevent and repair leaks. If you don't have such a program, start one. If you already are making the effort, make sure you document any resulting energy savings. You may be surprised at how fast leak prevention and repair can pay for itself. You'll have lower maintenance costs, less downtime, higher production, and safer workers. Lower overall system costs add up to more profitability.

Get in touch

Talk with our team about finding, assessing, and addressing leaks at your facility:

Up to 50% of skilled workers could retire withing the next 10 years - we can help relieve that pressure

Building an effective training program can help maintain the skills of your experienced workforce and assist your new staff in getting up to speed. Let us help with our free resource, “Three Steps to Building an Effective Plant Training Program."

Did you know last year alone Swagelok helped train approximately 40,000 individuals on their plant’s fluid systems? If you weren't one of them, we can assist you today. 

Building an effective training program

Not sure on where to start in building an effective training program for your plant and operations? Here is a quick overview on our free download:

• How to meet the varied needs of your labour force
  (Step 1: "Don't leave anyone out")
• Questions to ask when looking for a training provider 
  (Step 2: "Look for experienced instructors")
• The proper follow-up for your people after training
  (Step 3: "Manage the 'forgetting curve' ")
• Bonus tips for each step

Learn more about our training offerings, get in touch today. 

Additional resources:

• New Training Centre Has Plenty Of Room For Learning
• Swagelok Services Relieve the Other Kind of Pressure
• Seek Suppliers That Help You Prepare for Recovery

Cylinder assemblies take a beating in the field, so give them the attention they deserve

Edmonton Valve’s Cylinder Maintenance program will put your cylinders to the test with a visual inspection, assessment of threads, fittings, etc., and a full detailed report on their overall condition with recommendations for repairs and further testing if required. Contact us if you would like to set-up a discussion for your own cylinder maintenance program. 

Sample cylinder assemblies can face a rough life in the field. Unlike fittings or gauges, you don't just install them and leave them alone while they do their job, possibly for years. Cylinder assemblies go through an endless series of connecting and disconnecting and valves are continuously opening and closing. Valve stems are subject to wear over time as the seals are being exposed to different fluids, range of temperatures, and pressures.

The assembly may rattle around in a truck bed while being transported around the site. There's a lot of potential for sudden damage, such as someone dropping an assembly and breaking a valve handle, or long-term damage such as threads wearing out. Extreme cold weather that we have in Alberta definitely takes its toll too.

If you don't pay close enough attention to the wear and tear, leaks may develop at the connection points. In applications where a coating such as sulfinert is required, repeated use can wear away the coating and give you less accurate readings when the contents are analyzed.

Introducing our cylinder maintenance program

Just as you'd want a trained expert to inspect your car, trust the trained experts at Edmonton Valve & Fitting to inspect your cylinder assemblies. This year we have introduced our Cylinder Maintenance Program as one of our quality assurance services.

We will visually inspect your cylinders and any related assemblies, using a micrometer on the cylinder itself to ensure that the cylinder has not been deformed and is still within tolerance to operate safely under pressure. In our experience, sample cylinders tend to last a long time, but we have seen some instances of thread damage and rust or corrosion.

We'll assess the conditions of threads, needle valves, rupture disc valves, and fittings. When we're done, we'll write up a report for you, with detailed pictures of our findings. We'll make recommendations and, if you like, make repairs and tests.

Sample cylinders and their corresponding components all have a lifespan. This service is a great way to inspect these components to ensure they fall within certain safety parameters and guidelines.

All you have to do is decide how often you'd like us to perform an inspection (every three years or so is typical). One of our associates can visit your site to begin the conversation of a suitable starting point. This service is tailored to each specific customer and what results they are looking to achieve. We are excited about this new program and teaming up even more with our customers to provide a safe and efficient work environment. 

Request more information on this service here. 

Additional resources:

• Cylinders Are a Must For Grab Sample Systems
• Sample Cylinder Assemblies Offer Flexibility
• Edmonton Valve's 5 Pillar Approach to Services

We'll rent or sell the machines, and we'll teach you how to use them

Swagelok's Welding System M200 is available for rental purposes or for purchase. And if you're not sure how to use the machine, we can help you out with a training session to get you comfortable with the system. Just contact us and we will gladly help you out with your needs. 

There are times when you want to connect two pieces of tubing permanently rather than with a removable fitting. You could manually weld them together, but you'll get even better results with an orbital welder. That's because the computer-controlled machine precisely guides the welding electrode in a circle around the joint. The machine doesn't get tired either, so the last weld of the day will be just as good as the first.

The process is also known as Gas Tungsten Arc Welding, or GTAW. Lightweight, portable equipment makes it easy to do the work right at the job site.

Edmonton Valve & Fitting has a welder waiting for you, and we'll teach you how to use it.

Touch-screen ease

The Swagelok Welding System M200 power supply offers an easy-to-use touch-screen for trouble-free data entry and uncomplicated viewing of information. The screen layouts are simple to follow. You can program variables such as weld current and electrode speed, then track each weld. The Windows-based system monitors the welding, captures and compiles data in real time, and electronically transfers it from the welder to a computer. That makes documentation easy too.

Watch and learn

Just because a machine is automatic doesn’t mean it automatically does the job correctly. The quality of the work still depends on the skill of the operator. Even the fanciest orbital welding machine can't tell you if you need ordinary stainless steel tubing or more specialized material.

We offer a four-hour training course to get you up to speed.

The course is a mix of lecture and hands-on practice. We'll explain all the parts — the power supply, the fixture block, the welding head and more. We'll show you what a good smooth weld looks like (flat, not concave or convex). You'll learn how the machine reacts to different inputs. The level of the arc current, for example, controls weld penetrations. Travel speed affects both the width and the penetration of the weld.

Then you'll get a chance to hook up the power supply yourself, prepare some tubing for welding, and put the machine through its paces.

We don't rush you, because we know that proper setup is the key to good welding.

Rent or buy

You have two options: renting or buying the equipment.

If you're renting and have some experience operating an orbital welder, we may still ask a few questions such as when you last used a welder, and whether you've rented from us in the past. We'll also probably want to know what size of material you are welding, as that determines which of several heads to use. Then we might ask about wall thickness, which could determine which electrode is best.

As with any rental agreement, you assume responsibility for any damage, but we want to reduce the chances of you having any problems. If we aren't sure about your level of expertise, we'll insist that you take the training class.

Usually we can have a welder ready for you with only a couple of weeks notice. If you want to buy, it may take a little longer. But that extra time means you have more flexibility on scheduling the training class.

We'll be glad to tell you more. Send us a note through our website or call us at 780-437-0640

Additional resources:

• New Classes Offer Hands-On Training for IPT Fittings 
• Your Checklist for Tubing Quality
• Nice Looking Threads, but What Size Are They?

Stop by our booth #1076 to talk about hose, Grab Sample Modules and watch burst demonstrations

We are looking forward to heading south to Calgary for the 2018 Global Petroleum Show from June 12th - 14th. Not only are we teaming up with our friends at Calgary Valve & Fitting but with many Swagelok associates from across North America. Make sure you register to come to the show before May 31st for Early bird pricing - see you there!

Once again, Edmonton Valve & Fitting will join forces with other Swagelok affiliates for the big Global Petroleum Show in Calgary from June 12 through 14. We'll be in our usual spot: booth 1076, right inside the doors of Hall A. We'll have 16 people manning the booth in shifts, so you will find a knowledgeable fluid system expert any time from 10 a.m. to 5 p.m. on the first two days, and until 4 p.m. on the third day.

If you haven't been to the GPS in the past, you've been missing the leading exhibition and conference for oil and gas professionals. More than 50,000 trade professionals attend GPS, while more than 100 industry leading experts share their knowledge and understanding across the event’s expansive line-up of conference sessions.

The Swagelok advantage

At our booth we'll have Swagelok hose products on display, along with grab sample panels.

We're also excited to talk to you about MEP services, where we concentrate on three areas in a plant. The first is rotating equipment such as pumps and compressors. We have the specialized fittings that make working on those systems easier, such as Thermowell Tees to reduce the number of welds and up-sizing of pipe.

The second area is energy management and utilities. The third area is conversion from traditional piping to small bore tubing (2-inches and smaller).

Throughout the show we try to have some senior representatives in the booth, so you can have a serious conversation and expect to come away with some solid information. If we can't answer your question on the spot, we'll get your contact information and get back to you as soon as we can.

So excited we could 'burst'

We will also have our burst chamber on-hand that we use in our Swagelok Total Support training classes. Our Swagelok booth staff will be running demos and you can test your skills with pulling up a tube fitting and see what pressure the tubing bursts. We suggest you compete with your peers and see who has the higher burst pressure!

So stop by, say hello, and gather some free information and expertise.We look forward to seeing you in June.

For more on this topic, see:

• Seal Support Simplified: Call Edmonton Valve & Fitting
• Anatomy of a Swagelok Hose: What's Going on Inside and Out
• A Customer View on Edmonton's Tube Fitting & Installation Training

Free up labour while easily tracking where parts are being used

Fred Wedgewood, one of our mobile inventory truck drivers in the Edmonton area, shows off a Swagelok elbow in his Kenworth truck. If you want more information on our Inventory Management System and how we can partner this service with your business, contact us!

Can you think of a few places you'd rather deploy your labour force than on managing your parts inventory? At the same time, maybe you aren't ready to go all in on a high-tech product like the Robocrib system?

Not to worry. Edmonton Valve & Fitting has you covered with our Inventory Management System.

Simple tools

Our Inventory Management System requires only a smart phone and a handheld scanner to get you started. All you need to do is scan the barcode on the bin each time you take a part. Whenever you want, you can generate reports detailing how many of each component you are using, and where they are being used.

We'll drive our mobile inventory truck to your site on a regular basis and fill all the bins with the components you need. It's a dual-axle Kenworth truck, so you don't have to worry about us bringing enough to replenish your supply.

When the restocking order has been processed, our drivers are able to generate a priced packing slip on the spot and electronically send the information back to Edmonton Valve. This system reduces errors, saves time, and leaves the customer knowing exactly what they have received.

We can track what you are using and make sure you get timely refills.

Good for secure sites

Our inventory management system is a good option for locations where you don't have customers or contractors walking through the site, and you can operate it on the honor system.

In a fab shop, for instance, you don't have to wait for workers to tell you afterward what parts they have used. Just call up the ID number of the job, and you have an instant bill of materials.

This system is not product dependent. As long as the part has a bar code, you can track it.

We'll be glad to tell you more. Send us a note through our website or call us at 780-437-0640.

For more on this topic, see:

• Mobile Warehouse Brings Swagelok Parts to Far-Flung Locales
• Edmonton Valve Merchandisers Don't Just Deliver Product
• Are Your Fluid Systems Skating on Thin Ice?

This computerized vending machine tracks inventory and issues real-time reports

Edmonton Valve not only can help you get your inventory back on track with the RoboCrib system but we can vouch for it as we use the system ourselves with our Custom Solutions department to assist with inventory on our different projects. 

If your company has different budgets for different jobs on site, or you are a contractor running several jobs at once, it can be a chore to keep track of which parts are going where. Several of our customers have solved that problem with a parts vending machine called RoboCrib. It tracks inventory, issues real-time reports and frees up staff to do other jobs.

We can set up RoboCrib in a variety of sizes so you can store anywhere from 500 to 2,000 parts. The bins also are easy to reconfigure, so one machine can dispense parts as small as a single tube fitting, as large as a sample cylinder, or even bigger. The footprint of the largest of its models measures slightly more than five feet by five feet.

Tracking software

When someone needs a part, all they have to do is login on RoboCrib's touch screen with their username and password. You can set up RoboCrib so that different people have different authorizations as to which parts they can take, by part number, by job number or by purchase order.

RoboCrib brings the right part to the front and automatically opens the vending door, all in less than 10 seconds. You don't need to pay one of your own people to stand there handing out safety glasses or tube fittings, and jotting down all the relevant information.

You can set other limits too, such as how many items can be taken out per day, week or month. You can limit access by dollar amount, departmental budget, or time restrictions by shift. RoboCrib can send instant alerts to management when a job is using an abnormal number of components.

In all there are 150 different reports pre-designed and built into the system. If a contractor needs to bill a customer, there's no need to wait for a worker to turn in a ticket. All the information is stored in RoboCrib.

You don't even have to fill up the bins when inventory runs low. We'll come to your site with fresh inventory as often as once a week if needed with our mobile inventory services. 

Locker assignments

The company that makes RoboCrib also makes the AutoLocker for items such as laptops, iPads, power tools, gauges or any asset that needs to be tracked. Like the RoboCrib, the AutoLocker has a touchscreen for entering usernames and passwords. It's a modular system, so you don't have to get more lockers than you need. The locker modules are available in 12 different sizes for even further customization. You can even get a version with a power-charging option, so your workers will always have a fresh charged in the tool they need.

Probably the best endorsement of these systems is the fact that once they are set up, our customers stick with it. One has been using RoboCrib since 2006.

We’ll be happy to give you all the details. A quick call to 780-437-0640 is all it takes to get started, or you can send us a note through our website.

For more on this topic, see:

• Need Extra Protection for Hose? We Have You 'Covered'
• Insulated Tubing Gives You Temperature Control
• Are Your Fluid Systems Skating on Thin Ice?

Complex bends and large runs are easy thanks to computer controls

Need a 180-degree tube bend? No problem! Our CNC tube bender is fast and precise. Tube bending is one of our custom solutions, which you can learn more about here:

We love to show off our CNC tube bender when customers take a tour of our shop. At 10 feet long, three feet high and three feet wide, this machine looks like a brute. But while it's powerful enough to bend bar stock, we use it instead to bend tubing with delicate precision.

The CNC bender can handle any tubing from a quarter-inch diameter up to one inch, and any wall thickness. It can bend any angle, even 180 degree bends. Its size allows it to handle bends with a radius of up to 42 inches.

One more time

But the big advantage of the CNC bender is repeatability. CNC stands for "Computer Numerical Controls." Once we program your job into the computer, we can create exactly the bends you ask for every time, no matter how complex the combination of angles.

We can create hundreds of finished pieces, and each will be identical. And it's fast, so even if you just need a couple of simple bends in a piece of tubing, the CNC bender is still ideal for the job.

When we finish your job, we store the specifications in the computer forever with a unique identification number. If you gave us a drawing in 2010, you can use it to produce fresh copies today. As with any valuable database, we backup our data to guard against accidents.

Copying and improving

In fact, we don't even have to start with a drawing. Give us the part you want to replicate, and we'll put it in our vector machine that works with the CNC bender. The vector machine scans your part, produces a 3D drawing of it, and sends the information to the bender.

We don't have to worry about wasted tubing, because our machinery will tell us the exact length to cut, down to a thousandth of an inch.

Maybe you have a damaged piece of tubing that you need to replace. We can use that as the starting point to recreate the original. We'll scan it and adjust the drawing to return everything to its proper alignment. We'll even print out the new drawing for you.

Or maybe you aren't exactly sure what the finished part should look like. We can start a drawing and show it to you, then make any adjustments you want until the design meets your approval.

Even if the original part is fine but you want to revise the design, we can adjust the dimensions in the computer to add an inch here or a bend there. The CNC bender assigns a different part number to each version, so you can always go back to the original design if you want.

Quick turnaround

Because the CNC bender is so quick and efficient, we often can turn out a single-part order on the same day it comes in. More involved projects usually can be turned out within a week.

Next: Would you like a demonstration? Please contact us to schedule a time:

(Prefer to talk live? Please give us a call at 780-437-0640.)

For more on this topic, see:

• Tagging Hoses at Edmonton Valve & Fitting (blog article)
• Customers Rate Edmonton Valve's Performance (blog article)
• Forget Trial and Error; Take Our Tube Bending Course (blog article)

Value Impact Partnerships make it clear what our customers save each year

Edmonton Valve's mobile warehouse is just one of the many ways we are providing our customers with cost savings. The VIP program is a tool used to showcase the many cost savings we provide our customers.

For the past several years we have been offering a special kind of VIP Program to many of our customers. The letters stand for Value Impact Partnership, a way to show how Edmonton Valve & Fitting has evolved from a component supplier to a solutions provider and, most importantly, a valued business partner with our customers.

Extra service

Over the course of a year, we can provide services that help customers save time and money. For example, we often provide inventory management services at no extra charge. That means we may go to a customer once a month and check what they need for inventory, draw up an order and have the products delivered. This frees the customer's warehouse staff to do other work, and eliminates freight charges.

Our VIP program also includes:

• Supply chain efficiencies: The best parts are only the best parts if you have them when you need them. Edmonton Valve & Fitting makes sure you get them on time with solutions such as our mobile warehouse.
• Procurement enhancements.
• Energy management, field engineering and custom solutions services.
• Specialized training programs, safety installation, safe product selection, industry experts and seminars. Swagelok experts are glad to show you and your staff the latest developments in fluid system technologies, on site or online.
• Product evaluations, substitutions, fitting reclamation, and assistance with sourcing non-Swagelok products.

It adds up

It is not uncommon for us to perform more than 100 value-added events each year for a single customer. The cumulative savings can become substantial. While the savings will vary from company to company, they typically are more than 25 percent of what the customer spends with us each year.

That's what the VIP program tracks. We quantify those savings in a report. Usually we do it once a year, but we have recently automated many of our processes so that we can quickly gather information and report out savings whenever anyone wants to take a snapshot part way through the year.

Large and small

VIP is not just for large customers. Many smaller companies take advantage of our value added programs.

This year we ran 129 VIP reports, covering more than half of our yearly business. Many of these reports cover several customers plant or branch locations, which in itself is a benefit. Many of our customers are not aware of the extra services we are providing throughout their sites. Our VIP reports help them see what we do at multiple levels, giving them a greater awareness of the savings that are generated in various customer departments.

Would it make sense for your company to take part in our VIP program? Find out by calling 780.437.0640, or contacting us through our website. 

Additional resources

• Losing Steam? Send For Our Swagelok Energy Advisors
• Seek Suppliers That Help You Prepare for Recovery
• Swagelok Listens, Our Customers Reap the Benefits

University students in Munich rely on Swagelok in worldwide competition.

Swagelok fittings were a key component for the braking system on the WARR Hyperloop pod during the Hypeloop Pod Competition put on by SpaceX. Watch this short video to learn more.

Elon Musk is famous for two very different kinds of transportation: the Tesla electric car and the reusable rockets of Space Exploration Technologies Corp., better known as SpaceX. Now Musk is hoping to develop yet another transportation idea. This time it's a high-speed train that could cover more than 300 miles in less than 30 minutes. It's called the Hyperloop.

Unlike traditional rail transportation, the Hyperloop runs inside a tube with very low air pressure. The system is designed to move "pods" of people and cargo at close to the speed of sound while using very little energy.

The concept is still in the experimental stage, but already Swagelok parts are playing a role.

Competition

To give his idea a jump-start, Musk set up a competition involving teams of university students. Swagelok has sponsored a team of 30 students from the Technical University of Munich that has advanced to the finals. The team is part of a larger organization called the Scientific Workgroup for Rocketry and Spaceflight, whose German initials are WARR. Their design includes a compressor to suck the air from in front of the pod and stream it out the back, reducing the air resistance to zero.

You can watch the team at work in a five-minute video from Swagelok.

The Hyperloop competition gives students a chance to learn in a way that a regular academic course never could. Designing and assembling the pod takes them beyond classroom theory by getting their hands on the components. They have to take care of real-world details such as leaving enough room for each component, and other aspects of a project that aren't likely to come up until you actually start building it. The work also brings together computer science, mechanical engineering and civil engineering students from several countries. The students say they like Swagelok not only for the quality and reliability of the parts, but for the availability of technical help.

Safe and reliable

The students are using Swagelok parts in the braking system. At such high traveling speeds, there can't be any question about whether the brakes will activate safely when needed.

If the Munich team wins the competition, their work could end up having an affect on the transportation that people take every day. Maybe your next project won't change the world, but that doesn't make it any less important to you. Rely on the same high quality and expertise that the Munich students are using to move their project forward. Call us at 780-437-0640 or contact us through our website.

Additional resources

• Swagelok Parts Help Keep Eco Car Competitive
• Edmonton Valve & Fitting Goes To College
• The Importance of Oxygen Safety & Eliminating Potential Ignition Sources