water glycol hydraulic pump factory

The checkball pump’s ability to operate with a combination of high or low viscosity or lubricity fluids offers remarkable flexibility. Dynex hydraulic pumps operate within a wide range of recommended viscosities from 31.6 to 3,142 SUS (1,5 to 680 cSt). Dynex water glycol pumps are widely used in the offshore oil & gas industry.

Continental Hydraulics announced that it’s PVX vane pumps are now fire-resistant, as they are approved for water glycol to 2,500 psi. Water glycol fluids have proven to be an excellent fire-resistant hydraulic fluid option. This should open up new markets like food processing, steel manufacturing, automotive assembly or and other industry that typically use the water glycol fluids.

Hydraulic fluid performance, including water-glycols (W/G), depends on the chemical composition of the fluid and cleanliness. This article presents an overview of the effect of W/G fluid chemistry on pump wear. An overview of recommended analytical procedures to assure adequate long-term hydraulic and lubrication performance is provided. These procedures can result in substantial improvements in hydraulic pump longevity and performance.

Many industrial applications such as steel making, die casting, etc. require the use of hydraulic fluids that offer greater fire safety than that achievable with mineral oil. One of the most common alternatives to mineral oil for use in these applications is a water-glycol hydraulic fluid.

The performance of all hydraulic fluids, including W/G hydraulic fluids, depends on the composition of the fluid and on fluid cleanliness. Although there are numerous references describing analysis procedures for petroleum oil-derived hydraulic fluid, similar references describing the analysis of water-glycol hydraulic fluid are relatively rare.

Water-glycol hydraulic fluid formulations typically contain water (for fire protection), glycol (for freeze point protection), polyalkylene glycol (PAG) thickener, an additive package to provide corrosion and antiwear protection, antifoam/air release additive and dye for leak detection.

The performance of a hydraulic fluid depends on the particular additive and concentration used in the formulation. Substances that exhibit a marked effect on hydraulic pump wear, according to the ASTM D2882 test, are water, amines and antiwear additives. The ASTM D2882 test is conducted at 2,000 psi (13.8 MPa) for 100 hours and eight gallons per minute (30.6 L/min) in a Sperry Vickers V-104C vane pump.

Water content creates one of the most significant influences on hydraulic pump wear rate. Figure 1 shows that wear rates increase with increasing water content. Thus, it is critically important to control the water content of W/G hydraulic fluids if both fire-resistance and antiwear performance is to be maintained.

The primary function of the amine is to provide corrosion protection. Vapor and liquid phase inhibitory properties of an amine can be determined using the 200-hour Corrosion Test. This test is conducted by aerating the heated hydraulic fluid at 70 ± 2°C in contact with metal test coupons for 200 hours. The test coupons that are immersed in the fluid are: steel (SAE-1010, low carbon), cast aluminum (SAE-329), copper (CA-110) and brass (SAE-70C). Vapor phase corrosion effects are also determined using coupons of cast iron (G-3500) and steel (SAE-1010) which are suspended above the solution. Figure 3 illustrates a typical corrosion test cell.

Figure 3. Corrosion Test Apparatus is Convenient for Corrosion-Inhibitor Studies of Water-Glycol Hydraulic Fluids Under Laboratory Conditions. Immersed Metal Specimens are Separated by a Glass “Z-bar” in the Specific Order Shown. Vapor-Space Test Specimens are Hung from the Top of the Glass Test Cell. Fluid Temperature is Monitored with an Immersion Thermometer, Air is Blown into the Mixture Using an Aeration Tube, and a Cold-Water Condenser is Used to Reduce Fluid by Evaporation.

Fortunately, as shown in Figure 4, it is possible to formulate a W/G hydraulic fluid so that there will be minimal impact on wear with the inevitable loss of additive over time. Nevertheless, once the critical level is achieved there is a dramatic increase in wear rates with further decreases in antiwear additive concentration.

Hydraulic pump lubrication depends not only on fluid chemistry but also on both liquid and solid contamination. In W/G fluids, the most common liquid contamination is usually petroleum oils, which may enter the hydraulic system from numerous sources. Because petroleum oils are insoluble in the W/G they may be simply skimmed from the fluid reservoir. In practice, removal is often neglected for long enough periods that some of the additives adsorb into the mineral oil and are removed from the working fluid when that oil is skimmed from the surface of the reservoir. Every effort should be made to prevent this form of contamination.

Water contained in a W/G fluid can be lost through evaporation during normal hydraulic operation. Water loss increases the fluid’s viscosity. Water must therefore be added back to the system to maintain fire-resistance and to assure proper viscosity and system operation.

The most common methods for determining water content of a W/G hydraulic fluid are refractive index, viscosity and Karl Fischer analysis. Refractive index is the most commonly used and is readily determined using a portable temperature-compensated refractometer that provides readings in degrees Brix.

The principal limitation of water determination by refractive index is that refractive index is affected by any material, including contaminants, that may be present in the hydraulic fluid. Thus, it is advisable to crosscheck water analyses obtained by refractive index against at least one other analytical method. After the water concentration is determined, additional water should be added if necessary. Some suppliers provide tables such as Table 1, which provide water make-up levels without the use of the calibration plot represented by Figure 5.

Only distilled or deionized water with a conductance of less than 15 µmhos/cm (or a maximum total water hardness of 5 ppm has also been recommended), should be added to a W/G hydraulic fluid system. This is critically important because polyvalent metal ions such as Ca+2, Mg+2, Mn+2, etc. will react with the antiwear additive, usually an organic carboxylic acid, to form a polyelectrolyte complex salt (Formula 1) which appears as a white, soapy solid. This process must be prevented for two reasons. The first is that it will lead to continuous depletion of the critically important antiwear additive. Second, the presence of such precipitates, like any solid material, will increase wear.

The water content of a hydraulic fluid may also be determined by viscosity measurement. One common method of viscosity measurement is to follow the ASTM D445 procedure for kinematic viscosity.

By using the chart in Figure 6, viscosity vs. water content, the amount of water can be easily maintained within the necessary range for the fluid. Alternatively, a water make-up table based on viscosity, as shown in Table 2, may be obtained from the W/G hydraulic fluid supplier for the specific fluid being used.

The load-bearing capacity of a fluid film depends on fluid viscosity. Oxidative and thermal degradation processes will result in a decrease of fluid viscosity. Thus routine viscosity measurement is one of the best methods of monitoring fluid stability. However, such comparative measurements must be made at the same total water content.

The third, and most unambiguous, method of water determination is by Karl Fischer Titration (ASTM D1744). The advantage of Karl Fischer analysis is that it is a direct measure of water content, while viscosity and refractive index are both indirect measurements which are substantially affected by either contamination (refractive index) or fluid degradation (viscosity).

Amine concentration in a W/G hydraulic fluid is designated as reserve alkalinity and is conventionally reported as the volume in milliliters of 0.1N hydrochloric acid (HCl) required to titrate 100 ml of W/G fluid to pH 5.5. A typical titration plot is shown in Figure 7.

Figure 8. Two-dimensional Contour Plot - Effect of Formic Acid and Reserve Alkalinity on ASTM D2882 Wear Rates of a Conventional W/G Hydraulic Fluid. Wear Rate is Affected by Both Formic Acid Content and Alkalinity.

It has thus far been shown that hydraulic fluid quality and performance depends on fluid cleanliness and chemistry variation. On occasion, it is necessary to troubleshoot fluid performance in malfunctioning systems. In addition to the chemical and physical analyses described, it is often valuable to analyze any wear debris. Ferrography is one of the principal wear debris analysis methods. It can be used to determine the concentration and distribution of wear particles contained in the hydraulic fluid.

It has been shown that W/G hydraulic fluid performance, like all other hydraulic fluids, depends on both fluid cleanliness and fluid formulation chemistry.

Water, antiwear additive and corrosion inhibitor concentrations must be monitored to assure optimum fluid antiwear performance. Recommended analytical methods include:

While analysis by ion chromatography and ferrography are specialized procedures and may be conducted as required, analysis for water content, reserve alkalinity, viscosity as well as visual observations are critical and must be conducted regularly (usually by the fluid supplier).

If the hydraulic system is properly maintained and fluid performance is adequately monitored, excellent long-life hydraulic and lubrication performance with water-glycol fluids is achievable.

Ciekurs, P. Ropar, S. and Kelley, V. "Prediction of Hydraulic Pump Failures Through Wear Debris Analysis." Naval Air Engineering Center Report, NAEC-92-171. July 19, 1983.

They are used in particular in non-moving hydraulics (e.g. machine tools, presses, etc.) and in vehicles that operate in a confined space (electric forklifts, etc.).

The modular and compact construction with single and multiple pump versions permits a wide range of applications. In multiple pump systems up to 5 metering units can ...

The modular and compact construction with single and multiple pump versions permits a wide range of applications. In multiple pump systems up to 5 metering units can ...

... variable-displacement axial-piston pump, the Oilgear pump PVV line is ready. No matter what pressure and flow demands you face, these pumps rise to the challenge.

A hydraulic pump is the power source in a hydraulic system. It is driven by an engine or an electric motor and pumps oil from the hydraulic oil reservoir ...

... pressure requirements. From the 0.23 l/m SM pump to the 193 l/m XH with pressures up to 690 bar (10,000 psi) for most ranges and even up to 1,040 bar (15,000 psi) for the X pump.

Phillips 66® FR Fluid-Glycol is a water-glycol based fire-resistant HYDRAULIC FLUIDS developed for use in industrial hydraulic systems operating in areas subject to fire hazards. It contains sufficient water to snuff out a fire resulting from ignition of a fluid leak. It is suitable for use in hydraulic systems operating at 2,000 to 3,000 psi, and can withstand intermittent pressure spikes up to 5,000 psi.

Our original Micropac pumps were designed 35 years ago around the need to provide manual hydraulic power using low viscosity fluids and also to offer a wide range of seal options with short lead times and low cost.

The product addressed the common complaint that pumps are designed only with ball check valves for mineral oil and also special seals for use with demanding fluids become a ‘special’ with the associated extra cost. Our equipment was totally at home on very low viscosity fluids and special seals could be provided at modest cost and short lead time.

For many years, the principal specialist fluids that we used were “Skydrol” phosphate ester aircraft fluid and also water glycol fluids used in defence and offshore. Since then, we have seen increasing use of synthetic fluids. Great care is needed in specifying the right equipment for these, so talk to our Engineering Department about your exact needs.

Micropac pumps are widely used for Eastman ‘Skydrol’ phosphate ester aerospace fluid. Our MW-3 hand pump is most commonly specified due to the 316 stainless steel construction.

Our PPS 100% 316 stainless component pump would be used in a Skydrol system piped up from discrete hydraulic components. The pump is available with Swagelok twin ferrule tube fittings or a range of male and female threaded adaptors.

The Offshore Industry has a different set of fluid requirements, using a wide range of media. For us, water glycols have always provided engineering challenges. Water glycols cover a wide range of fluids from very low viscosity offshore control fluids through to fire resistant oil substitute hydraulic fluids such as OX40 commonly used in marine systems, mining and in steelmaking. Here the hand pump must be able to function with the viscosity of the fluid, but as important for many users is corrosion resistance. 316 stainless pumps are commonly used for water glycols.

Our MW-3 Micropac hand pump range is widely used for water glycols. It provides a very long service life both in respect of wetter parts and also external components, so is used by the Defence, Marine and Offshore industries.

Our PPS 100% 316 stainless component pump would be used in a water glycol control system or power system piped up from discrete hydraulic components. The pump is available with Swagelok twin ferrule tube fittings or a range of male and female threaded adaptors.

Hydraulic fluid is a pressure transmitting medium that transfers the energy generated by a hydraulic pump to a hydraulic actuator on a device such as a cylinder or motor. In order to achieve the precise, accurate and stable operation of the hydraulic equipment, the hydraulic fluid is required to have lubricating performance, rust and corrosion prevention properties, temperature and viscosity properties, stability and anti-foaming properties. Of the hydraulic fluids available, the fire-resistant hydraulic fluid "HYDOL" is used on hydraulic equipment such as die casting machines producing aluminum automobile parts, steelmaking equipment and presses, and it protects this plant equipment from fires.

Hydraulic systems often operate with at high pressures and speeds while having severe metal to metal contact. Applications can range from vane, gear and piston hydraulic pumps to numerically controlled robotics. DuBois offers multiple hydraulic fluid series formulated to reduce metal to metal contact, increasing the life and efficacy of the hydraulic unit.

The Oilgear line of pumping products is focused on extreme reliability when pumping high water content fluids (HWCF, HWBF) or alternative fluids at high pressure. Below is a partial listing of challenging applications and fluids for which the Oilgear pump product line has proven successful.

Oilgear pumps are some of the most reliable pumps available for classic hydraulic media.  For the sake of brevity, classic hydraulic fluids are not listed here.

Remove particulate and tramp oils simultaneously to extend water-glycol life, reduce pump and component wear, improve machine efficiency, and minimize downtime.

Particulate and tramp oils deplete additives in water-glycol, increasing machine wear and corrosion and shortening fluid life. Also, contamination damages pumps and components, interferes with valve functionality, and causes failures and downtime. If you’re experiencing any of the following, it’s time to look for a new industrial filtration system:

Particulate contamination is constantly working its way into your hydraulic system, accumulating in water-glycol from machine wear and dust ingression. New machines and even brand-new fluids aren’t even clean from the manufacturer. All these contaminants increase downtime by shortening fluid and component life.

Tramp oils can get into water-glycol through cross-contamination or reservoir leaks. These oils float on the fluid surface and can absorb critical additives, increasing wear and corrosion to your machine. Our water-glycol filters adsorb tramp oils, removing them from your fluid reservoir. With COMO, you can:

Advanced Fluid Systems is proud to offer hydraulic repair services for hydraulic pumps and motors, from gear pumps to vane pumps to the largest radial piston pumps, regardless of brand. Our inventory includes seals, parts and re-manufactured pumps available for immediate shipment.

100HP programmable variable frequency drive (VFD) test system for mineral oil and water glycol fluids that allows us to test pumps with electronic controls.

Castrol AnvolTM WG 46 is an HF-C type water-glycol fire-resistant hydraulic fluid, containing anti-wear additives and corrosion inhibitors. It provides excellent protection against rust and vapor phase corrosion. In hydraulic pump tests, Anvol WG 46 has shown high levels of anti-wear performance. Its foam resistance, low temperature flow, emulsion stability and storage stability are also excellent.

Anvol WG 46 is for use in hydraulic systems where, in the event of fluid leakage, there is a significant risk of ignition. Examples of applications include furnace doors, die-casting machines, forging machinery and mining equipment. It can be used in vane, gear or piston-type pumps with pressures up to 3000 PSI. As with any water containing fluid, continuous high temperature leads to excessive evaporation. The water content should be checked regularly in service and any corrections made by addition of distilled or de-ionized water. Occasional monitoring of alkalinity is recommended to ensure the correct level of corrosion inhibition. Care should be taken to ensure the hydraulic system is designed for using water glycol-based fluids. Care should also be taken to ensure the compatibility of Anvol WG 46 with paints, seals and metals, and also ensure that the hydraulic pumps and filters used are suitable. A thorough draining and flushing procedure should be followed when converting from other fluids to water glycol-based solutions. Anvol WG 46 is fully compatible with nitrile, neoprene, silicone, nylon, butyl rubber and fluropolymer seal materials. Anvol WG 46 meets the fire resistance requirements of: 7th Luxembourg Report FM Global 6930

Using fire-resistant lubricants is a cost-effective option compared with installing mechanical fire-suppression equipment. With a 42–44% water content, Shell Water-Glycol S2 CX is an HFC type, fire-resistant hydraulic fluid designed for use in industrial equipment operating in areas subject to fire hazards, including in the steel, aluminium, die-casting, mining, glass and tunnel boring industries. It has a higher ignition temperature and lower flammability than mineral oils, and its glycol (diethylene glycol) content enables the fluid to be used in all seasons.

The fluid uses an innovative friction modifier to provide excellent pump lubricity, which can help to extend equipment service life and reduce maintenance costs. In the Vickers V-104 vane pump test, only 10–15 mg of wear was recorded after 100 hours at 2,000 psi and 65°C (ASTM D7043).

Featuring a high level of anti-wear protection, Shell Water-Glycol S2 CX is engineered to offer increased resistance to mechanical shear and has a stable viscosity that helps to protect components against wear.

Provides corrosion protection to a wide variety of metals, including aluminium, copper, brass, cast iron, steel and others commonly used in hydraulic systems.

Water based hydraulic systems have been traditionally used in underground mining applications and in the high temperature areas of steel mills and foundries