Lt3690 maintenance workshop

LT3690 MRO TrainingOptBro

3/8/2007

9:52 AM

Page 1

Visit us on the web for more information about maintenance workshops.

Henkel – Your partner worldwide

MAINTENANCE WORKSHOP Reliability starts here…

MAXIMIZE THE WORKSHOP BENEFITS With the Loctite® Maintenance Toolbox!

The Loctite® Maintenance Toolbox is designed to fit in a mechanic’s tool chest. It has been pre-packed with the newest technologies for increasing plant and equipment reliability.

Part Number 38956 KIT CONTAINS: Loctite® 220™ Threadlocker, Medium Strength/Wicking, 10 ml

Loctite® 565™ PST ® Thread Sealant, 50 ml

Loctite 222MS Threadlocker, Low Strength/Small Screw, 10 ml

Loctite® QuickStix™ 561™ PST ® Pipe Sealant with PTFE, 19 g

Loctite QuickStix 248 Threadlocker, Medium Strength, 9 g

Loctite® 587™ Blue, High Performance RTV Silicone, 70 ml

Loctite QuickStix 268 Threadlocker, High Strength, 9 g

Loctite® 641™ Retaining Compound, Low Strength, 10 ml

Loctite 2440 Threadlocker, Primerless/Medium Strength, 10 ml

Loctite® 660™ Quick Metal ® Retaining Compound, 50 ml

Loctite 2760 Threadlocker, Primerless/High Strength, 10 ml

Loctite® QuickStix™ C5-A® Copper Anti-Seize, 20 g

Loctite 518 Gasket Eliminator Flange Sealant, 50 ml

Loctite® 7649™ Primer N™, 1.75 oz. aerosol can

Loctite 545 Thread Sealant, Hydraulic/Pneumatic, 10 ml

Do it Right User’s Guide

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CHOOSE FROM ADDITIONAL HENKEL SERVICES:

Henkel Corporation Engineering Adhesives 1001 Trout Brook Crossing Rocky Hill, CT 06067 U.S.A. www.henkelna.com/mro www.loctite.com/mro

DOCUMENT COST SAVINGS:

Promote your hard work by documenting how you were able to cut costs, eliminate failures, reduce component consumption and avoid downtime.

OPERATION STOP LEAK:

Let us identify air and hydraulic leaks in your plant. We’ll provide you with the tools to eliminate the reoccurrence of these leaks to save you money.

PUMP REBUILD:

Let us show you how and where to use Loctite® brand products to increase pump reliability.

INVENTORY CONSOLIDATION:

Let us conduct a shop chemical review to help you consolidate purchasing efforts. This will enable you to better manage the shop chemicals in the plant.

APPLICATION ASSISTANCE:

Let our expert engineering staff assist you with specific product and maintenance applications.

U.S.A. Henkel Corporation Engineering Adhesives 1001 Trout Brook Crossing Rocky Hill, Connecticut 06067 Tel: 860.571.5100 Fax: 860.571.5465

Canada Henkel Canada Corporation Engineering Adhesives 2225 Meadowpine Blvd.

Mississauga, Ontario L5N 7P2 Tel: 1.800.263.5043 (within Canada) Tel: 905.814.6511 Fax: 905.814.5391

Loctite, 220, 222MS, 248, 268, 518, 545, 561, 587, 641, 660, 2440, 2760, 7649, C5-A, Gasket Eliminator, Primer N, PST, Quick Metal and QuickStix are trademarks of Henkel Corporation, U.S.A. © Henkel Corporation, 2007.

All rights reserved. 4304/LT-3690C (2/07)

… with your skilled tradesmen, at the base component level during installation, repair, and rebuild of all your equipment.

LT3690 MRO TrainingOptBro

3/8/2007

9:52 AM

Page 3

MAINTENANCE WORKSHOP

MAINTENANCE WORKSHOP TRAINING SYLLABUS Hands-On Product and Reliability Training

AFTER A MAINTENANCE WORKSHOP Your skilled tradesmen will have the knowledge and the tools to:

Standard Training Syllabus:

SAVE TIME • Reduce routine maintenance tasks • Reduce standard repair time • Reduce redundant repairs

TRAINED, MOTIVATED, AND EQUIPPED PERSONNEL, DRIVE COSTS DOWN! AIR LEAK COST CALCULATOR

REDUCE ENERGY COSTS • Air leak 1/16" @ 100 psi @ $0.065 per kWh = $842.00 lost per year • Loose connector on 480 volt, 30 amp, 3 phase motor = 13% more energy needed to run IMPROVE SAFETY • Improve safety by eliminating personal injury hazards

Line Pressure at 100 psi Diameter of Opening (inch) 1/32

Cubic Feet of Air Loss/Year 849,139

CFM Loss* 1.62

Cost per Year $210

1/16

6.49

3,401,798

$842

1/8

26

13,628,160

$3,375

1/4

104

54,512,640

$13,498

3/8

234

122,653,440

$30,371

Cost per kWh

REDUCE FLUID CONSUMPTION • Hydraulic leak @ 1 drop/second @ $5.00/gallon = $2,025.00 lost per year • Reduce clean up and disposal costs

$0.065

*CFM loss may vary based on the shape of the opening and assumes facility maintains air pressure 8,760 hours per year.

OIL LEAK COST CALCULATOR Gallons Lost

IMPROVE RELIABILITY • Quality production • Extend Mean Time Between Failure • Reduce minor stoppages for adjustment • Fewer needless variables for Planned Maintenance • Enlarged reliability culture

Leakage Rate One drop in 10 seconds

Per Day 0.112

One drop in 5 seconds

0.225

6.75

81

$405.00

One drop per second

1.125

33.75

405

$2,025.00

3.75

112.5

1,350

$6,750.00

24

720

8,640

$43,200.00

Three drops per second Stream breaks into drops Cost per gallon*

Per Annual Month Gallons Lost 3.36 40.3

Annual Cost to Plant $201.50

$5.00

*Typical gallon costs range from $1.00 to $2.00. However, the costs associated to leaks need to be considered, such as: clean-up labor, absorbents, transaction, shipping, storage, recycling, and disposal.

THREADLOCKING • How a threaded fastener works • Advantages and disadvantages of mechanical locking devices • Chemical Threadlockers º How they work º Product selection How to select the right product How substrates affect performance Temperature and other environmental factors º Application techniques • Hands-on demonstrations THREAD SEALING • Types of threads and fittings • Causes of leaks • Chemical Thread Sealants º How they work º Product selection How to select the right product How substrates affect performance Temperature and other environmental factors Application techniques º • Hands-on demonstrations

Hands-on training Covers all trades Conducted on-site Training materials supplied Review common failure causes and prevention

• Standard 2 hour workshop can be tailored to meet your needs through a plant tour and pre-survey • In-plant follow up

º Design and service factors º Gasket materials and dressings º Assembly problems • Form-in-place gasketing basics • Product selection

º Rigid cast flanges vs. flexible flanges º Service factors • Anaerobic and silicone (RTV) gasketing • Hands-on demonstrations RETAINING

• Types, classes, and typical uses of cylindrical fittings

• Potential fit problems and possible solutions • Retaining Compounds

º How they work º Product selection How to select the right product How substrates affect performance Temperature and other environmental factors Application techniques º • Hands-on demonstrations

Additional Maintenance Solution Training Modules: WEAR PREVENTION AND REBUILD

• Use coatings to provide wear prevention and impact resistance • Restore worn parts or protect new components

METAL REBUILDING AND SHAFT REPAIR

• Rebuild and repair pumps, shafts, and components • Use metal-filled epoxies that are machinable and have high compressive strengths

FLOOR SAFETY

• Prevent slips and falls with anti-slip floor systems

LUBRICATION

• Basics of anti-seize, moly, oils, and greases • When and where to use which product and why

FLOOR AND CONCRETE REPAIR

• Repair concrete floors and make them stronger • Increase impact, chemical, and wear resistance

BONDING

• Assemble parts quickly and easily • Make bonds that are stronger than mechanical methods

GROUTING

• Use epoxy grouts to avoid popping and cracking of concrete bases • Increase impact and chemical resistance

BELT REPAIR

• Repair cuts, gouges, and worn edges on belting • Return equipment to service quickly

EMERGENCY REPAIR AND SPECIALTY PRODUCTS

• Make long-term repairs to parts • Return equipment to service quickly

MAINTENANCE WORKSHOP FEATURES • • • • •

GASKETING

• Why gaskets fail