Unit 24: Applications of Pneumatics and Hydraulics

Unit code: J/601/1496 QCF level: 4 Credit value: 15

OUTCOME 2

TUTORIAL 7 – HYDRAULIC FLUIDS

The material needed for outcome 2 is very extensive so there are ten tutorials in this outcome. You
will also be completing the requirements for outcome 1 which is integrated into it. The series of
tutorials provides an extensive overview of fluid power for students at all levels seeking a good
knowledge of fluid power equipment.

2 Understand the construction, function and operation of pneumatic and hydraulic

components, equipment and plant
Pneumatic equipment: types, construction, function and operation e.g. air compressors, coolers,
dryers, receivers, distribution equipment, fluid plumbing and fittings, drain traps, FRL air
service units, valves, actuators, seals
Hydraulic equipment: types, construction, function and operation e.g. fluids, pumps, motors,
actuators, reservoirs, accumulators, fluid plumbing and fittings, valves, filters, seals, gauges
Performance characteristics: air compressors e.g. volumetric efficiency, compression ratio,
isothermal efficiency; hydraulic pumps e.g. operating efficiency, losses, flow rate, operating
pressure, shaft speed, torque and power

On completion of this tutorial you should be able to do the following.

 Explain the ideal properties of a hydraulic fluid.

 Describe and explain the purpose of the different additives put into fluids.

 Explain the identification codes for fluids.

 Explain the different types of fluids and their applications.

 Use compatibility tables for fluids and system materials.

 Explain how to get maximum life from the fluid.

 Explain how to sample and test fluids for quality.

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1. INTRODUCTION

The efficient running of hydraulic machines depends upon using the correct fluid and keeping the
fluid in good condition. Always use the fluid recommended by the manufacturer of the hardware.

Filters and good system design are also essential if the fluid is not to deteriorate. The power pack
(pump and reservoir unit) plays a vital role in maintaining the quality of the fluid.

2. PROPERTIES

The following are properties required of hydraulic fluids.

1 COMPRESSIBILITY

Liquids are very difficult to squeeze into a smaller volume. This is why hydraulics are ideal
for precise motion control. If air is mixed with the fluid it becomes slightly compressible and
loses this property. Tests to measure compressibility consist of squeezing the fluid into a very
rigid vessel by a screwed plunger and measuring the pressure resulting.

2 VISCOSITY

The viscosity of a fluid determines how easily it flows. Fluids with a low viscosity such as
water flow easily but fluids with a high viscosity such as thick oil, flows with some difficulty
and this results in a loss of pressure in the pipes and fittings. Fluids with low viscosity do not
lubricate very well so the right balance between pressure loss and lubricity is required.
Viscosity is measured with viscometers of various types. The preferred units are centi-Stokes
but many other units exist such as Redwood Seconds and they may be converted from one to
the other with tables.

3. VISCOSITY INDEX

The viscosity of a fluid usually decreases as it gets hotter. This means that a fluid may lose its
lubricity as it warms up or flows with difficulty when cold. Oil with a low viscosity index will
change very little but one with a high index will change a lot. This property may be improved
with chemical additives.

4 AIR ABSORPTION AND RELEASE

Liquids will absorb gas under pressure and release it when the pressure is released. This may
be seen with fizzy drinks. A good hydraulic fluid will not absorb air easily and will release it
quickly without causing froth and foam. Chemicals may be added to improve these properties.
Froth and foam on the surface of the reservoir are really many bubbles with a large surface
area. This enables oxygen to be absorbed into the fluid causing oxidation. Chemicals to
prevent the formation of foam are also used.

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6 OXIDATION

Oxidation is chemical combination of elements in the fluid with oxygen. This causes the oil
to thicken and produce varnishes which stain the components surface. The life of the oil is
much reduced. Chemicals may be added to reduce the oxidation rate but the fluid should be
kept away from air as much as possible. Foam and cascading in the reservoir are the main
reason for fluid and air mixing.

7. CORROSION

Hydraulic fluids can cause corrosion of metals. This is avoided by using compatible materials
and by adding chemicals to the oil.

8. WEAR

Chemicals may be added which cause the fluid to deposit a surface film at places where
surfaces are pressed together such as on the flanks of gears in gear pumps and motors. This
prevents wear taking place.

9. POUR POINT

The pour point is the lowest temperature at which the fluid will flow from a beaker when
tipped up. It is possible to add chemicals to reduce this temperature for working in cold
climates.

10. FLASH POINT

The flash point of a fluid is the temperature of the fluid at which vapour given off will ignite
on contact with a naked flame. The apparatus to measure this is called a Pensky-Martens
apparatus.

3. TYPES OF FLUIDS

The original hydraulic fluid was water which was alright with cast iron components but it would
freeze in cold weather and it evaporated in hot conditions. Water is still used for some applications,
especially when emulsified with oil. The most common fluids are made by refining mineral oil.
Special fluids such as fire resistant fluids are made from a variety of materials.

Mineral oils can meet most of the requirements listed above. The only drawback with them is their
low flash point of 150° to 250°C. Fire resistant fluids are used where there is fire risk. Water is a
suitable F.R. fluid in some cases but has obvious problems. Adding 10% oil to water in emulsified
form helps provide the necessary lubrication. A mixture of 40% water in oil with special agents
produces a good F.R. fluid. Synthetic F.R. fluids have flash points as high as 600°C. These fluids
are very expensive.

The viscosity of a fluid is covered in ISO3448, BS4231. Basically the viscosity stated is the
viscosity that occurs at 40oC in cSt units. For example a fluid designated HM32 is a mineral oil as
defined overleaf with a viscosity of 32 cSt at 40oC.

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The main categories of fluid are as follows:

1 MINERAL OILS DIN 51524/ISO6743/4 BS6413/4

Mineral oils are produced by refining crude oil and adding certain substances to improve their
quality.

Type HH is a non inhibited refined mineral oil.

Type HL has anti-rust and anti-corrosion additives.
Type HM has anti-wear additives as well as the above.
Type HV has a viscosity index improver as well as all the above.

2 FIRE RESISTANT FLUIDS

Type HFAE is an oil in water emulsion.

Type HFAB is a water in oil emulsion (40% water emulsion)
Type HFAS is a chemical solution in water.
Type HFC is water-polymer (water - glycol) solution.
Type HFDR is a synthetic fluid made from phosphate ester.
Type HFDS is a synthetic fluid made from chlorinated hydrocarbons.

Water/Oil Emulsions
In this case the oil is the majority substance (about 60% oil). Special additives cause the water
to disperse (emulsify) in the oil. When the fluid comes into contact with a hot surface, the
water turns to steam and prevents fire. The lubrication properties are good.

Water Glycol
Type HFC has 60% glycol 40% water mixed together. The water forms into a solution instead
of mixing. They have the advantage of working at lower temperatures than emulsions and
produce a better temperature-viscosity characteristic.

Phosphate Esters
Type HFD-R. These fluids have good fire resistance and do not ignite until heated to 550°C or
higher. The lubrication properties are similar to mineral oils. The main problem is that they
are chemically active and will strip paint from a surface and attack certain kinds of rubber, so
special seals, hoses, accumulator bags, etc. have to be chosen. They melt electrical insulation
if they leak onto cables. The cost of these fluids is exceptionally high.

Typical FR fluids commercially available are:

Shell Iris 904 (Water/oil emulsion)
Walkers Aquacent (Water/oil emulsion)
Vaughan-Houghtosafe 620 (Water glycol)
Fina Hydran FR32s and Houghtosafe 1120 (Phosphate Ester)

Environmentally Friendly Fluids

These are made from plant oil. Types are : HTG or Trigliceride, HPG or Polyglycol and
synthetic ester.

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4. COMPATIBILITY OF FIRE RESISTANT FLUIDS WITH MATERIALS.

When considering Fire Resistant Hydraulic Fluids, either in the design or installation stage it is
essential to have in mind their degree of compatibility with materials normally encountered in
hydraulic systems. The following table describes in general terms the compatibility of various types
of fluids with a variety of materials and is intended as a useful guide. It is advisable, however, to
finally check compatibility at least with the material supplier.

C = Compatible
NC = Not Compatible Water Glycol Phosphate Water-in-Oil
LC = Limited Compatibility Based Fluids Ester Emulsion
Fluids
Metals
Ferrous C C C
Copper & Brass C C C
Bronze LC¹ C C
Cadmium & Zinc NC C C
Lead NC C NC
Aluminium LC² C C
Magnesium NC C NC
Tin & Nickel C C C
Paints &
Finishes Common Industrial
Oil Resistant NC NC NC
Epoxy & Phenolic C C C
Vitreous Enamel C C C
Plastics
Acrylic (Includes C NC C
Perspex)
Styrene C NC C
Epoxy C C C
Phenolic C C C
Silicone C C C
P.V.C. C NC C
Nylon C C C
Polypropylene C C C
P.T.F.E. C C C
Rubbers (Elastomeric Seal Materials)
Natural C NC NC
Neoprene C NC C
Nitrile C NC C
Butyl C C NC
Ethylene Propylene C C NC
Polyurethane NC LC³ NC
Silicone C C C

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 C = Compatible Water-Glycol Phosphate Water-in-Oil
NC = Not Compatible Based Fluids Ester Fluids Emulsion
LC = Limited Compatibility
Viton (Fluorocarbon Based)
C C C
Other seal materials
Leather NC LC LC
Cork including Rubber NC LC NC
Impregnated
Filter Media
Cellulose - Phenolic C C C
Resin Treated
Metallic - As metals -
Earth Type NC NC NC

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5. CARE OF HYDRAULIC FLUIDS

70% of faults in hydraulic systems are due to contamination of the fluid. All possible precautions
should be taken to prevent air, water and solid matter entering the fluid. This means that when
assembling units, strict cleanliness is needed. Such assembling should take place in a special dust
free room with clothing designed to prevent human contamination. Any work carried out should be
followed by cleaning procedures such as flushing out particles from pipes. To further protect the
system, filtering systems should be used. Filters generally should be capable of removing particles
down to 10 microns and in some cases down to 3 microns. (1 micron = .001 mm).

Oil is a very expensive commodity. It is important to choose the right grade for the job and obtain
the maximum life possible by caring for it. The condition of the fluid should be regularly checked
and records kept for each machine.

SAMPLING

Oil samples are taken in order to check the quality of the oil. The following method should be
used:

1 Take one sample from the top of the tank immediately after use.
2 Take another sample from the bottom of the tank after allowing time for it to settle (e.g.
Monday morning).
3 Keep the samples in a clean metal or plastic container.
4 Label the samples and record its details such as:
Date, Machine number, oil type, date of last check, date when installed.

The samples should be tested for various properties. Some tests can be conducted simply on the
spot. Others are done in the laboratory.

SPOT TESTS

1 Compare the sample with new oil.

Appearance Smell Condition Action

Clear and sparkling Sweet Good None

Dark and cloudy Rancid Deteriorated Change it
Cloudy, no colour Sweet Water present Settle and separate

2. Hot plate test

Drip a drop onto a hot plate. If it sizzles, it contains water.
3. Filter test
Put a drop into the middle of a filter paper. The spot spreads. Any dirt is left at the middle as a dark
patch.

PIPE-WORK

Pipe work is covered in the next tutorial but it is worth noting that pipes carrying oil are normally
painted brown and if they carry oil at pressure they have bands of salmon pink colour on them.

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 SELF ASSESSMENT EXERCISE

You will need to have read the tutorials on fluids and reservoirs to answer the following
questions.

1. List the additives in oil identified by the code HV.

a. ____________________________________

b._____________________________________

c._____________________________________

2. What happens normally happens to the VISCOSITY of a fluid when it get hotter.

_________________________________________________________

3. State the names of THREE types of fire resistant fluid

_________________________________________________________________

___________________________________________________________________

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4. What does viscosity measure?

___________________________________________________________________

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5. State 2 seal materials which are compatible with phosphate ester fluids?
___________________________________________________________________

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6. State two hydraulic hose materials which are compatible with phosphate ester fluids?
___________________________________________________________________

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7. What is the meaning of viscosity index?

___________________________________________________________________

___________________________________________________________________

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8. State two effects a fluid with a poor viscosity index would this have on a machine running hot?

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9. List 2 reasons why hydraulic oil may overheat when in use.

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10. What is the difference between an oil/water emulsion and a water/oil emulsion?
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11. State two disadvantages of water as a hydraulic fluid.

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12. State 2 reasons why oil should not be stored in open containers.

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13. State the danger associated with oils with a low flash point.
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14. State two measures you would use to ensure that a hydraulic machine is not topped up with the
wrong type of fluid.
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___________________________________________________________________

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15. State the correct colour coding for a pipe carrying mineral hydraulic oil under pressure.

___________________________________________________________________

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16. State the reason why hydraulic oil should not be allowed to cascade into the tank on return.
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17. State how water may form in a hydraulic tank over a period of time.
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18. State the consequence of letting air mix with mineral oil.
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19. State 2 consequences of using a tank which is too small for a hydraulic machine.
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20. State the purpose of baffles inside hydraulic tanks.

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