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Challenges

From the coke oven plant and sinter plants to the pickling plant and cold rolled finishing line, reliable equipment is a must. Expensive downtime due to un-scheduled maintenance can be avoided throughout the steel making process by utilizing LOCTITE maintenance solutions.

Coking Plant  

Coking Plant

Challenge 1: Loosening of fasteners on Vibratory Screen

Despite use of locking devices, heavy vibrations can cause the fasteners to work themselves loose.

Solution:Lock Fasteners with LOCTITE 277 Threadlocker

Challenge 2: Failure of vibratory screen casing and shaft

Heavy vibrations cause fretting corrosion and allow ingress in casing and shaft.

Solution: Secure shaft with LOCTITE 641 Retaining Compounds

Challenge 3: Sealing for coke oven door

There is a strict limit on the emissions from the coking process. The sealing strips used generally have poor profile congruency with the oven door and tend to warp over a period of time.

Solution: Seal coke oven door flanges with LOCTITE SI 596 Flange Sealant

Sintering Plant  

Sintering Plant

Challenge 1: Loosening of fasteners on screening equipment

Heavy vibrations and harsh operating conditions can lead to self-loosening and seizure of sintering equipment fasteners.

Solution: Secure fasteners with LOCTITE 263 Threadlocker

Challenge 2: Leaks from cooling air pipes

Leaks from cooling air pipes can lead to loss in production efficiency and high electricity costs.

Solution: Seal threaded pipe connections with LOCTITE 567 Thread Sealant

Blast Furnace  

Blast Furnace

Challenge 1: Leaks from steam pipe and fittings

Leak from threaded connections of pipe systems carrying steam are dangerous, costly and reduce overall operational efficiency.

Solution: Seal threaded pipe connections with LOCTITE 567 Thread Sealant

Challenge 2: Loosening of conveyor bolts

Vibrations and shock loads can lead to self-loosening of conveyor bolts which can damage the belt and cause excessive noise.

Solution: Secure conveyor bolts with LOCTITE 263 Threadlocker

Challenge 3: Leaks from hydraulic cylinders

Oil leak from end cover of hydraulic cylinders leads to unnecessary loss of process fluid and cleanup requirement.

Solution: Seal end covers with LOCTITE 518 Flange Sealant

Steel Rolling Plant  

Steel Rolling Plant

Challenge 1: Loosening and breaking of housing mill liner bolts

Heavy vibrations of roller housing due to the rotational motion of steel roller can lead to self-loosening of mill liner bolts. The extreme working conditions can also lead to seizure of the bolts which can break during service.

Solutions: Secure mill liner bolts with LOCTITE 243 Threadlockers

Challenge 2: Roller spin in housing

Heavy shock loads due to high rotational speeds can cause the rollers to loosen within the housing.

Solution: Fit roller in housing with LOCTITE 648 Retaining Compounds

 

Electric motors and generators are the prime drivers of all machinery. Any failure in these, can lead to costly downtime. Proactive maintenance can minimize the risk of such unscheduled breakdowns and increase service life of the motor driven equipment.

Housing and End Plates  

Housing and End Plates

Challenge 1: Loosening of End Plates

Vibration and shock loads can lead to loosening of the through bolts that keep end covers bolted to the housing. This can lead to misalignment and can cause damage to the motor.

Solution: Secure end cover through bolts with LOCTITE 222 Threadlocker

Challenge 2: Loosening of Assembly Screws and Cover Screws

The threaded assemblies can work themselves loose under dynamic loads. This can lead to excessive vibration in the machine and can damage the housing and frame.

Solution: Lock assembly and cover screws with LOCTITE 243 Threadlocker

Challenge 3: Ingression of Moisture and Foreign Particles

The interface between end plates and the housing allow foreign particles to enter the motor housing which can significantly reduce the motor performance.

Solution: Seal the end plate and housing interface with LOCTITE 518 Flange Sealant

Shaft Mountings  

Shaft Mountings

Challenge 1: Loosening of Bearing or Commutator

Electric motors pick up the required rotational speed with a jerk. This repeated jerk can lead to loosening of the shaft mounted component like bearing and commutator. Loosening of cylindrical fittings can reduce transmitted torque and damage the components.

Solution: Mount cylindrical components with LOCTITE 641 Retaining Compound

Challenge 2: Fretting Corrosion on Bearing

The air gap trapped between the bearing and shaft allows corrosion to build up and seize the bearing on the shaft. In such cases, the bearing will have to be replaced with a new one, resulting in downtime and scrap cost.

Solution: Fit bearings on shaft with LOCTITE 641 Bearing Retainer

Mounting Bolt  

Mounting Bolt

Challenge: Misalignment Due to Loose Mounting Bolts

Motor mounting bolts keep the motor frame in place and maintain alignment with the driven equipment. However, the mounting motor bolts can loose clamp loads under vibrational shocks and cause misalignment which can damage the rotational components.

Solution: Fasten mounting bolts with LOCTITE 277 Threadlockers

 

Most industrial centrifugal pumps carry a significant capital equipment value. It is important to extend their service lives and ensure that they run efficiently. Proactive maintenance can reduce the risk of breakdowns and increase pump reliability and longevity.

Bearing Frame & Housing  

Bearing Frame & Housing

Challenge 1: Oil Leaks from Threaded Assemblies

The gaps between threads of drain plugs, oiler nipples, fittings etc. can lead to oil leaks due to constant pressure changes within the bearing housing. Not only do these leaks increase costs but also lead to the seizure of fittings and safety hazards.

Solution: Seal threaded assemblies with LOCTITE 567 Thread Sealant

Challenge 2: Bearing Spinout, Corrosion and Component Damage

Bearings are prone to spinning either on their shafts, or within their housings, resulting in damage to these parts regardless of whether they have been pressed, shrunk or slip fitted in place. The gap that exists between a bearing and shaft is an area where rust can form and cause damage to the parts.

Solution: Fit and seal bearings with LOCTITE 641 Bearing Retainer

Frame Adapter  

Frame Adapter

Challenge 1: Gasket Failure between Bearing Frame and Frame Adapter

Leaks from the frame connection can mean money lost in oil consumption and potential safety hazards. This happens because pre-cut gaskets cannot tackle the gap between flange surfaces. Flange imperfections are potential leak paths that pre-cut gaskets cannot seal and they relax over time to make the gaps large enough for leaks to happen.

Solution: Seal flanges with LOCTITE 518 Flange Sealant

Challenge 2: Fastener Loosening and Corrosion to Frame Adapter Mounting Bolts

Bolts are always under strain caused by torque, vibration, shock, thermal expansion and contraction. The gaps between the engaging nuts and bolts allow these external factors to challenge the clamp load.

Solution: Lock and seal bolts with LOCTITE 243 Threadlocker

Pump Casing  

Pump Casing

Challenge: Corrosion and Seizure of Pump Casing Bolts

The severe pump environments of constant temperature, pressure and humidity changes cause the pump casing bolts to corrode and seize. Seized casing bolts make pump maintenance difficult and create additional labor associated with drilling and tapping the bolt hole.

Solution: Seal and Protect Bolts with LOCTITE 243 Threadlocker

Challenge: Leaks between the Stuffing Box and Casing

The use of cut gaskets has inherent problems. Neither does it occupy all flange irregularities, nor does it maintain elasticity. This leads to creation of leak paths that corrode and damage the flange surfaces.

Solution: Seal flanges with LOCTITE 518 Flange Sealants

Coupling  

Coupling

Challenge: Misalignment and Damage Due to Coupling Loosening

Couplings are held in place by a key and a set screw. If the set screw loosens, the coupling can begin to slide along the shaft and disengage, or it can begin to wallow out the keyway.

Solution 1: Lock set screws in place with LOCTITE 222 Threadlocker (for > ¼") 
Solution 2: Lock set screws in place with LOCTITE 243 Threadlocker (for > ¼")

Pump Base Mounting  

Pump Base Mounting

Challenge: Misalignment Due to Loose Mounting Bolts

Vibration and possible impact shock can work to loosen the mounting bolts. Loose bolts result in a loss of clamp load, which allows the pump to lose its level and aligned configuration.

Solutions: Maintain alignment by securing mounting bolt with LOCTITE 263 Threadlocker

 

Industrial gearboxes play an important role in processing and manufacturing facilities. Reliable operation over a long service life, with minimum maintenance, is a key requirement. Proactive maintenance can minimize expensive downtime, enhance reliability and dramatically cut costs.

Housing  

Housing

Challenge: Damage and Corrosion in Housing due to Bearing Spin

Bearing outer races are prone to spinning within their housings, resulting in damage to the housing. This damage is regardless of whether or not they have been pressed or shrink fitted in place. Once the clearance increases, the air gap leads to fretting corrosion, causing damage to the parts.

Solution: Fit bearing in housing with LOCTITE 641 Retaining Compound

Housing and Cover Assembly  

Housing and Cover Assembly

Challenge 1: Gasket Failure Between Upper and Lower Housing of a Split Gearbox

Oil leakage from failed gasket between upper and lower housings of split case gearbox can increase risk of gearbox running low on oil and increase overall oil consumption, safety hazards and clean-up costs.

Solution: Seal flanges with LOCTITE 518 Gasketing Compound

Challenge 2: Loosening and Corrosion of Housing and Cover Fasteners

Cover fasteners can loosen when exposed to torque, vibration, thermal expansion and shock loads. Once the fasteners become loose, the preload on the gasket is lost and the gasket fails. Additionally, cover fasteners can corrode and seize making gearbox maintenance difficult and hence create additional labour associated with drilling and tapping of the fastener hole.

Solution: Secure cover fasteners with LOCTITE 243 Threadlocker

Lubrication and Cooling System  

Lubrication and Cooling System

Challenge: Leakages from Threaded Fittings

Pressure and temperature changes within the gearbox can lead to leaks from threaded fittings such as oil drain plug, oil inlet, housing ventilation, oil pump, oil filter, oil gauge, coolant pump, pressure and temperature control unit and all pipe work.

Solution: Seal threaded assemblies with LOCTITE 567 Thread Sealant

Shaft Mounted Components  

Shaft Mounted Components

Challenge 1: Spun Bearings on Shaft

Bearings are prone to spinning on the shaft due to dynamic load on the assembly which produces axial loads higher than the original calculations. This bearing spin leads to damage on both shaft and bearing which may necessitate component replacement, causing unplanned downtime and scrap costs.

Solution 1: Fit bearings on shaft with LOCTITE 641 Retaining Compound (gap < 0.15mm)
Solution 2: Fit bearings on shaft with LOCTITE 660 Retaining Compound (gap < 0.5 mm)

Challenge 2: Loosening of Fitted Gears

Gears are prone to loosening on the shaft under dynamic loads, leading to reduction in torque transmitted.

Solution: Fit gears on shaft with LOCTITE 638 Retaining Compound

Gearbox Mounting Bolt  

Gearbox Mounting Bolt

Challenge: Misalignment Due to Mounting Bolt Loosening

Vibration and shock loads can loosen gearbox and motor mounting bolts, leading to misalignment which can cause damage to both the machines.

Solution: Secure Mounting Bolts with LOCTITE 277 Threadlocker

 
 
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LOCTITE Solutions Across Industries
LOCTITE offers solutions tailored to solving industry-specific challenges, which can optimize manufacturing processes and drive down cost.

Industrial Manufacturing Maintenance

Industrial equipment manufacturers design and build machines that make other machines and end products.

LOCTITE products help industrial equipment manufacturers in maintaining smooth operations and high productivity of all machines.

Problem Areas
  • Maintenance of Electric Motors

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  • Maintenance of Pumps

    Maintenance of Pumps

  • Maintenance of Gearbox

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Paper and pulp

The harsh environment of the paper and pulp industry leads to a variety of maintenance challenges.

LOCTITE can help in eliminating the challenges and increase the productivity of machines.

Problem Areas
  • Maintenance of Electric Motors

    Maintenance of Electric Motors

  • Maintenance of Pumps

    Maintenance of Pumps

  • Maintenance of Gearbox

    Maintenance of Gearbox

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Rubber and Plastic

The versatile end products manufactured put immense stress on the processing machinery.

LOCTITE products help the machines run smoothly under extreme working conditions, while maintaining high productivity.

Problem Areas
  • Maintenance of Electric Motors

    Maintenance of Electric Motors

  • Maintenance of Pumps

    Maintenance of Pumps

  • Maintenance of Gearbox

    Maintenance of Gearbox

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Automotive Components

Auto component manufacturers need to deliver within tight deadlines and comply with strict product and process quality.

LOCTITE solutions help in fast repair and proactive maintenance of machines to ensure plant reliability.

Problem Areas
  • Maintenance of Electric Motors

    Maintenance of Electric Motors

  • Maintenance of Pumps

    Maintenance of Pumps

  • Maintenance of Gearbox

    Maintenance of Gearbox

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Textiles

In order to keep up with the dynamic industry changes, the process machinery should run without unplanned breakdowns.

LOCTITE solutions help in corrective, preventive and proactive maintenance to ensure process reliability and high productivity.

Problem Areas
  • Maintenance of Electric Motors

    Maintenance of Electric Motors

  • Maintenance of Pumps

    Maintenance of Pumps

  • Maintenance of Gearbox

    Maintenance of Gearbox

Read more
 

Food and Beverage

Food and Beverage processing industry needs to comply with stringent regulations. Challenges such as loosening due to vibration, leakages and corrosion, threaten the everyday performance of processing machinery.

LOCTITE products help to combat the above challenges and increase machine reliability.

Problem Areas
  • Maintenance of Electric Motors

    Maintenance of Electric Motors

  • Maintenance of Pumps

    Maintenance of Pumps

  • Maintenance of Gearbox

    Maintenance of Gearbox

Read more
 

For Queries and More Details,

Email - customer.enquiries@henkel.com

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