PROBLEMS AND SOLUTIONS

Transcription

1 HIGH PRESSURE FLUID SYSTEM FIRE RESISTANT FLUIDS PROBLEMS AND SOLUTIONS General Electric HPU Westinghouse HPU

2 HYDRAULIC FLUID USED Phosphate Ester Fluid Fyrquel Ð Reolube Ð Great Lakes/Forsythe Polyol Ester Fluid Quintolubric 822 and 888 Ð Akzo/Supresta US/ICL Quaker Chemical Corp. Polyalkylene Glycol (PAG) Eco Safe EHC 46/68 American Chemical Technologies

3 HYDRAULIC FLUID SYSTEM PROBLEMS The biggest single problem with the hydraulic fluid system is CONTAMINATION

4 CONTAMINATION/SOURCES & SYMPTOMS Particulate Water Naturally Occurring/ Accelerated by Water/ Resistivity/ Gels Resistivity Air Breather/ Condensation/ Fluid Storage/ Water Coolers Acids Air Breather/ Worn Components/ New (dirty) Fluid/ Maintenance Lowered by Acids, Water, Particulates/ Etching/ Component Damage Gels & Varnish Fluid reaction with Metal Salts/ Gel Formation/ Varnish Deposits

5 BIOLOGICAL ISSUES Phosphate Ester fluids are difficult to handle Skin and Eye Irritant If Fumes are Inhaled Phosphate Ester fluid is difficult to dispose of Respiratory Problems Nerve Damage if Inhaled Marine Pollutant (heavier than water) Phosphate Ester and Polyol Ester fluids react poorly with insulation and seal material Polyalkylene Glycol (PAG) fluids have very low resistivity (new fluid)

6 PROBLEM Phosphate Ester Fluid Polyol Ester Fluid Causes system contamination problems Present personnel hazards Disposal is difficult and expensive Not compatible with Phosphate Ester Fluids Causes system contamination problems Polyalkylene Glycol (PAG) Low Resistivity of new fluid leaves very little margin for error in avoiding damage to system components caused by 䇾free streaming electron damage䇿

7 SOLUTION Bio-Syn EHC Fluid Produced by Hill and Griffith Company and distributed by National Power Fluids Specifically designed for the steel casting industry where use of fire a resistant fluid is critical to safety. Factory Mutual Global approved as Fire Resistant Fluid High performance hydraulic fluid with superior lubricity, and viscosity index. Bio-Syn is both biodegradable, and safe to handle New Fluid Resistivity >55 G-ohm-cm resulting in eliminating 䇾free streaming electron damage䇿 to system components.

8 IMPROVED LUBRICITY OF BIO-SYN EHC FLUID Provides superior lubrication and improved wear protection for component in tough applications

9 FIRE RESISTANCE BIO-SYN EHC FLUID Is inherently fire resistant Higher Flash Point than Phosphate Ester and Polyol Ester Fluid Is Factory Mutual approved under the latest Spray Flammability Protocol (SFP). Will not create the black, acrid, toxic smoke as is typical to phosphate esters in combustion. Flush Point >550oF Fire Point >650oF

10 VISCOSITY INDEX (VI) Phosphate Ester Fluids Viscosity index of 0 Notorious for low temperature start up difficulty due to viscosity changes with temperature change. BIO-SYN EHC Fluid Minimum viscosity index of 215 Maximum stability of the viscosity over a wide range of temperature Improved pump suction characteristics due to minimal viscosity change over a wide range of temperature.

11 ELASTOMER COMPATIBILITY Phosphate Esters and Polyol Ester are well known for their chemical attack of seals, hoses, and bladder bags; thus, it is mandatory to resort to expensive Viton, Teflon, or Fluorosilicone. Bio-Syn EHC fluid does not create phosphoric acid and therefore does not have a tendency to either swell or delaminate even conventional elastomers, such as high nitrile 䇾Buna N䇿.

12 ACID GENERATION Phosphate Esters commonly produce phosphoric acid, which is not only corrosive to hydraulic systems, but presents itself as a primary irritant to skin and eyes. Phosphate Esters are the primary cause of gels and varnish formation in EHC System Phosphate Esters contribute to 䇾Free Streaming Electron Erosion䇿 and require special filtering media to absorb the strong acids produced. Bio-Syn EHC fluid will not produce phosphoric acid under any conditions.

13 ENVIRONMENTAL COMPATIBILITY BIO-SYN EHC Fluid Bio-Syn EHC Fluid has been tested and shown to biodegrade to industry prescribed levels of biodegradability within 7 days. It also passes the existing standards for safe aquatic toxicity, reaching safe levels as required over a period of 96 hours.

14 SERVO CLEANLINESS BIO-SYN EHC fluid is triple filtered down to 3 micron absolute, minimum. This ensures a significantly cleaner fluid than is currently available anywhere in the market place and helps maintain tight dynamic clearances in expensive servo valves and pumps, while allowing for optimal hydraulic component efficiency and extended life of the system

15 FLUID COMPARISON CHART Hydraulic Oil Phosphate Ester Polyol Ester Polyalkylene Glycol (PAG) ISO Grade Viscosity Index >215 Specific Gravity < < Acid Number mg KOH/g Bio-Syn EHC Flash Point (of) 238 > >550 Fire Point (of) >400 > >650 Autoignition Temp (of) >500 > >1050 Burns Continuously Self Extinguishes Self Extinguishes Self Extinguishes Self Extinguishes No Yes Yes Yes Yes 25 mg loss 20mg loss < 5mg loss < 10mg loss <4mg loss Toxicity No Yes No No No Biodegradable No No Yes Yes Yes Unknown All Viton, Teflon, Fluorosilicone Viton, Teflon, Fluorosilicone Yes All Spray Flammability Factory Mutual SFP Approved Pump Wear ASTM 2882 Resistivity (G-ohm-cm)-new fluid Elastomer Compatibility

16 TESTING PERFORMED 50/50 MIX TEST 50 % BIO-SYN 50 % USED EHC FLUID PARAMETERS MONITORED FILTER PLUGGING CLARITY OF FLUID TOTAL ACID NUMBER VISCOSITY HPU TEST STAND

17 TESTING CONTINUED TOTAL ACID NUMBER ACID NUMBER REMAINED STABLE EVEN WITH TEMPERATURE SPIKES UP TO 204 F. VISCOSITY VISCOSITY OF FLUID MIX REMAINED STABLE DURING THE TEST.

18 50 % BIO-SYN EHC 50 % USED FRYQUEL EHC FILTER PLUGGING NO INDICATION OF EITHER THE 3 um PRESSURE FILTER OR THE 10 MICRON RETURN FILTER BEING PLUGGED. CLARITY OF FLUID n FILTERS WERE ANALYZED AND FOUND MINIMAL AMOUNT OF RESIDUE AND NO INDICATION OF ADDITIVE INTERACTION OR FALLOUT. SAMPLE SHOWED NO SIGN OF FLUID CLARITY CHANGE 84 HOURS 8 MINUTES AT 154 F AVERAGE BUT WITH SPIKES TO 207 F.

19 CONTINUED TESTING Bio-Syn EHC Fluid was continuously laboratory tested under extreme conditions for an additional fourteen months. No significant performance issues or problems were evident as a result of the additional testing.

20 FLUID MAINTENANCE REQUIREMENTS Run Side Stream Conditioning System 24/7/365 Take monthly fluid samples and send them to National Power Fluids for free analysis

21 FLUID MAINTENANCE REQUIREMENTS Keep the Fluid Clean 15/13/10 (ISO 4406)

22 FLUID MAINTENANCE REQUIREMENTS Keep the Fluid DRY Less than 300ppm Use Dry Air Blanket (Stealth)

23 FLUID MAINTENANCE REQUIREMENTS Neutralize Fluid Acids Less than 1.5 mg KOH/g Ion Exchange Filters

24 BE PROACTIVE NOT REACTIVE

25 Thank You Barry Sibul Company 1400 S. Ocean Blvd., Suite N-902 Boca Raton, FL Phone Fax Web site