Fluid Power Institute Report

Report Zero Leak Gold® Plug Testing

EPCO commissioned an independent study to determine the estimated torque values for Zero-Leak Gold Plugs. The torque value testing that was conducted by the Fluid Power Institute which is located at the Milwaukee School Engineering. The FPI reported that the Zero-Leak Gold Plug torque values were approximately 60% of their old style, O-ring only, SAE J514 ORB plug counterparts. The Fluid Power Institute torque values reported apply to the parameters and conditions of the test only and may be used as a starting point for determining the torque values for specific applications. Begin any torque value effort with the torque values established by the Fluid Power Institute report. If those value are insufficient, clean both the port and plug, re-install the plug and increase the torque value by 5%. Continue that process until a satisfactory torque value is established. The torque value for Metric size Zero-Leak Gold Plugs may be determined by using the torque value of the nearest equivalent ZLGP SAE size plug in the FPI Report and follow the ‘5% increase’ process until a satisfactory torque value is established.

Zero-Leak Gold Plug Test Report

Table 1.

EPCO Zero-Leak Gold Plug Testing Torque Values
  Report Torque
Values (ft-lbs)
 
Material
SAE & Zero-Leak Gold Plug Size Ductile Iron Aluminum SAE Torque Value Percentage of SAE stated Torque
-2 2 2 3 ± .4 58.8%
-3 3 3 5.6 ± .4 57.6%
-4 7 7 8.9 ± .8 72.0%
-5 9 9 12 ± 1.6 66.1%
-6 11 11 18.7 ± 2 58.8%
-8 28 28 35 ± 4 71.7%
-10 46 46 55 ± 4 77.9%
-12 51 51 75 ± 4 64.5%

Table 2.

EPCO Zero-Leak Gold Plugs Proof and Burst pressure Testing
Block
Number
Proof Test Burst Test
Pressure (psi) Fitting sizes
on Manifold
TIME AT
PRESSURE
Burst
Pressure (psi)
Mode of
Failure
Aluminum Ductile Iron
SAE
1 6000 -- 2,3,4 120 sec 21,769 No failure
2 6000 -- 5,6,8 120 sec 23,111 No failure
3 6000 -- 10,12 120 sec 23,339 Manifold thread failure (SAE #10 Port)
4 -- 10,000 2,3,4 120 sec 21,699 No failure
5 -- 10,000 5,6,8 120 sec 26,453 No failure
6 -- 10,000 10,12 120 sec 22,567 No failure

Table 3.

Removal Torque
Zero-Leak Gold Plug Size Aluminum Average Removal Torque
(ft-lbs)
Ductile Iron Average Removal Torque
(ft-lbs)
Initial Torque
(ft-lbs)
Removal Torque
(ft-lbs)
Initial Torque
(ft-lbs)
Removal Torque
(ft-lbs)
2
2
2
2
2
2
3.75
6.5
5.25
--
5.2
--
2
2
2
3
2.75
6.25
--
4.0
--
3
3
3
3
3
3
4
6.25
6.25
--
5.5
--
3
3
3
4.25
4.25
4.5
--
4.3
 
4
4
4
7
7
7
28.5
31.5
27
--
29.0
--
7
7
7
7.25
6.75
11.75
--
8.6
--
5
5
5
9
9
9
27.5
28
31
--
28.8
--
9
9
9
11
11.5
10.75
--
11.1
--
6
6
6
11
11
11
34.25
34
31
--
33.1
--
11
11
11
22.5
12
14
--
16.2
--
8
8
8
28
28
28
80
75
75
--
76.7
--
28
28
28
40
31.5
29
--
33.5
--
10
10
10
45
45
45
115
125
120
--
120.0
--
45
45
45
135
95
125
--
118.3
--
12
12
12
51
51
51
155
160
185
--
166.7
--
51
51
51
60
85
85
--
76.7
--