A Final Stage Presentation on

EVALUATION OF FIRE RESISTANT HYDRAULIC FLUID TO REPLACE CONVENTIONAL MINERAL OIL IN NUCLEAR INDUSTRY

Presented by

Zeeshan Ahmad (132090007)

Under the Guidance of

Dr. V.M.Phalle Associate Professor & TPO

VEERMATA JIJABAI TECHNOLOGICAL INSTITUTE (An Autonomous Institute Affiliated to University of Mumbai)

Mumbai 400019 &

Mr. N. L. Soni, OS /Mr. P. K. Mishra, SO/E REFUELLING TECHNOLOGY DIVISION

Reactor Design & Development Group Bhabha Atomic Research Centre

Trombay, Mumbai

• Contents 1. Introduction

• Problem definition

• Objective

• Summery

2. Literature review • Classification of Hydraulic Fluids

• Classification of Fire-Resistant Hydraulic Fluids, Their Properties and Uses

• Properties of Hydraulic Fluids and Their Effect on System Performance

• Requirements for Fire-Resistant Hydraulic Fluids

• Tribological Properties of Hydraulic Fluids

• Effect of Gamma Radiation on Properties of Hydraulic Fluid

3. Methodology • Tribological Evaluation of Hydraulic Fluids

• Gamma Irradiation of Hydraulic Fluids

4. Discussion and results

5. Conclusion and future scope

6. References

1.Introduction

1. Objective •Study of different types of hydraulic fluids and their properties and selection of fire resistant hydraulic fluid based on previous data available and system requirements.

•Study of tribological behaviour of different hydraulic fluid and selection of standard method of evaluating tribological properties based on our requirements.

•Preparation and submission of report on tribological behaviour of hydraulic fluids.

•Conclusion based on experimental data of both the hydraulic fluids.

•Planning and preparation of sample for gamma radiation of hydraulic fluids inside a gamma chamber located at ISOMED, south side of BARC.

•Measurement of viscosity, viscosity index of radiated oil samples at different temperatures and conclusion based on experimental data.

2. Summery

a) Literature Reviewed •Study of different types of hydraulic fluids

•Selection of fire resistant hydraulic fluid

•Study of properties of hydraulic fluids and their effect on system performance

•Study of different tribological test methods as per ASTM and ISO standards

•Study of effect of gamma radiation on properties of hydraulic fluids

2.Literature Survey

Sr. No. Author Name & Book Title Literature

1 Engineering Design Handbook of Hydraulic Fluids, Headquarters’, U.S. Army Materiel Command, April 1971.

Classification of Hydraulic Fluids , Tribological Properties of Hydraulic Fluids

2 ‘Lubricants, Industrial Oils and Related Products – (Class L) – Classification – Part 4: Family H (Hydraulic Systems)’, ISO Standard 6743

Fire-Resistant Hydraulic Fluid Types for Industrial Applications

3 ‘Hydraulic Fluid Power – Fire-Resistant (Fr) Fluids – Guidelines for Use’, Bureau of Indian Standards, New Delhi-110002.

Requirements for Fire-Resistant Hydraulic Fluids

4 H. H. Zuidema, ‘The Performance of Lubricating Oil’, Reinhold Publishing Corp., N. Y., 1959.

Friction, Wear, and Lubrication: Terms and Definitions

Sr. No. Author Name & Book Title Literature

5 S. Sharma, S. Sangal, K. Mondal, ’ On the optical microscopic method for the determination of ball-on-flat surface linearly reciprocating sliding wear volume’, Wear 300 (2013) 82–89

Measurement and Calculation of Wear, A model for calculation of the wear volume in case of linearly reciprocating sliding wear test has been studied in this paper to get accurate and quick results. The model proves to be an effective tool for the calculation of the wear volume.

6 Charles Spar, Hydraulic Fluids and Their Applications, ASME Publication 64 WA/LUB-14.

Relative radiation resistance of various hydraulic fluids.

7 R.O .Bolt and J.G. Carrol, ‘Effect of radiation on aircraft lubrications and fuels’, California Research Corporation, WADC Technical Report No 56- 646, Part II, ASTIA Document No. AD 151176. April 1958.

Change of properties of lubricant because of gamma irradiation

8 Zeeshan Ahmad, P.K.Mishra, ‘Determination of Effect of Gamma Radiation on Petroleum based Hydraulic Fluid - ENKLO-68’ RTD Report, BARC, Mumbai

Tribological data of gamma irradiation on hydraulic fluids.

Literature Survey conti..

Sr. No. Bench Type Friction and Wear Tester Literature

1 Timken Tester Federal Test Method 6505

A steel block is pressed against a rotating, cylindrical steel ring

2 Almen Tester

a cylindrical rod is rotated in a split bushing which is pressed against it

3 Falex Tester Federal Test Method 3807 & Federal Test Method 3812

A cylindrical rod is rotated between two hard V-shaped bearing blocks which are pressed against the rod

4 Four-ball Tester ASTM D-2596-67T, Federal Test Method 6514 & ASTM D-2266-64T

In the four-ball machine (often called the "Shell" Four-ball Tester) a 1/2-in.-diameter steel ball is rotated in contact with three stationary similar balls which are clamped in a fixed position

5 SAE Tester Federal Test Method 6501

In the SAE machine, two cylinders aligned axially and in contact with each other are driven at different speeds. One of the cylinders may be driven in either direction. The pieces revolve under a flooded lubrication condition from the test liquid held in a cup.

7 ASTM Designation G133-05(2010), ‘Standard Test Method for Linearly Reciprocating Ball-on-Flat Sliding Wear’, ASTM International, West Conshohocken, PA, 2010, www.astm.org

A flat specimen and a spherically ended specimen (here in called the “ball “specimen), which slides against the flat specimen. These specimen moves relative to one another in a linear, back & forth sliding motion, under a prescribed set of conditions.

Bench Type Friction and Wear Tester

3.Methodology

1. Tribological testing of hydraulic fluid

• Objective: • The main objectives of this test was

• To evaluate the wear characteristics hydraulic fluids at different conditions

• To compare these wear characteristics of the two oil samples with each other and also with actual pump test

• Apparatus and materials: • This test has been carried out at Refueling Technology Division (RTD), BARC Mumbai

• A reciprocating sliding wear and friction machine (Plint and Partner TE-70) was used based on ASTM G133 Procedure B

• Bearing steel plate SS-52100 and bearing steel balls SS-52100 of 1/2 inch (12.7 mm) diameter were used as fixed specimen and moving specimen respectively.

• Other test conditions:

• Test Procedure:

Load

Typical Contact Geometry TE70 Reciprocating Wear & Friction Machine

Oil Name Temperature (°C) Load(N) Frequency (Hz) Sliding

Distance (M)

Stroke Length

(MM)

Time (Sec)

Oil-A

FRHF

POE

65

15 10 400 1 20000

15 20 400 1 10000

25 10 400 1 20000

Oil-B

Mineral 65

15 10 400 1 20000

15 20 400 1 10000

25 10 400 1 20000

Oil-A

FRHF

POE

90

15 10 400 1 20000

15 20 400 1 10000

25 10 400 1 20000

• The following test procedure was followed as per ASTM standard G133 – 05

1. Specimens on which experiments were carried out (e.g. plate & ball) were cleaned thoroughly using acetone and ultrasonic cleaning machine. The samples were dried by using hot air.

2. The sample bath was cleaned using acetone & was dried with hot air.

3. The specimens were cleaned after they were secured in place in the test fixture by wiping with acetone and then with lint free tissue paper.

4. The ball specimen was gently lowered upon the flat specimen & it was also ensured that the reciprocating drive shaft motion was horizontal & parallel to the surface of flat specimen.

5. The test load was applied. It was confirmed that the desired oscillating speed had been set before starting the test

• Test Parameters:

Sr.

No.

Parameter As per ASTM Standard ( Procedure B) Parameters Used For This

Test

1 Applied Normal Force- 200 N 15 N, 25 N

2 Ball Tip Radius 4.76 mm ½ in (12.7 mm)

3 Stroke Length 10 mm 1 mm

4 Test Duration sliding Distance 400 m sliding Distance 400 m

5 Frequency of oscillation 10 Hz 10,20,10 Hz

6 Type of motion produced by

the oscillating drive system

Not Specified. It can be Sinusoidal velocity

profile, triangular velocity profile

Sinusoidal velocity profile

7 Ambient relative humidity 40 to 60 % 60%

8 Ambient Temperatures 150 ± 2°C 65°C

9 Medium Lubrication Lubrication

• Measurement and Calculation of Wear:

1. Wear measurement of ball specimen:

• Owing to the nature of this type of test, the wear on ball specimen may not be circular or flat

always therefore refer the following which applies.

• If the ball appears flat but not circular, the average of the maximum and minimum dimensions of the scar is taken as effective ball scar diameter (D).

• Pin scar measurement may be made by removing the ball specimen holder and placing the wear scar portion under the microscope. A calibrated ocular or a photo-micrograph of known magnification may be used to measure scar dimensions.

As per ASTM G99-05(2010) Volume loss of Ball in mm3 is calculated using following formula

𝑉𝑏 𝑣𝑜𝑙𝑢𝑚𝑒 𝑙𝑜𝑠𝑠 ,𝑚𝑚3 =

𝜋(𝑤𝑒𝑎𝑟 𝑠𝑐𝑎𝑟 𝑑𝑖𝑎. ,𝑚𝑚)4

64 × (𝑏𝑎𝑙𝑙 𝑟𝑎𝑑𝑖𝑢𝑠,𝑚𝑚)

𝑉𝑏 =𝜋𝐷4

64 ∗ 𝑅

Where Vb= Wear volume for ball scar of diameter D in mm3

D = Ball scar diameter in mm R = Ball radius in mm Note: This is an approximate geometric relation that is correct to 1 % for (wear scar diameter/ball radius) <0.3, and is correct to 5 % for (wear scar diameter/ball radius) <0.7. The exact equation is as given below.

Volume loss of ball (Vb) is given by, 𝑉𝑏 = 𝜋ℎ 6 [3𝐷2 4 + ℎ2]

Where ℎ = 𝑅 − [𝑅2 − 𝐷2/4]1/2 D = Wear scar diameter R = Radius of Ball Wear rate of ball is calculated using following formula.

𝑘 =𝑉𝑏𝑃 ∗ (𝐿 × 10−3)

Where k = Wear rate of ball in mm3/Newton. Meter Vb = Wear volume for ball scar of diameter D in mm3 P = Load in N L = Sliding Distance in mm

2. Wear of Flat specimen:

Wear of Flat specimen is calculated using following formula

𝑉𝑓 =[8 ∗ 𝑤 ∗ 𝑑 ∗ 0.001 ∗ (𝑙 − 𝑤) + (𝜋 ∗ 𝑤3 )]

12

Where, w = width of wear scar in mm

d = depth of wear scar in mm

l = length of wear scar in mm

Ball SS-52100, 15 N, 10 Hz, 20000 sec Ball SS-52100, 25 N, 20 Hz, 10000 sec

Typical photographs indicating Ball wear

Plate SS-52100, 15 N, 10 Hz, 20000 sec Plate SS-52100, 25 N, 20 Hz, 10000 sec

Typical photographs indicating Plate wear

• Results and Discussion 1. Effect of Temperature on Coefficient of Friction

0.05

0.06

0.07

0.08

0.09

0.1

0.11

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35

Co

eff

icie

nt

of

Fric

tio

n

η*V/P(Stribeck Parameter)

Stribeck Curve for OIL-A and OIL-B

OIL-A

OIL-B

Regime 1 Regime 2 Regime 3

0.079

0.089

0.081 0.081

0.088

0.05

0.06

0.07

0.08

0.09

27 65 90

Co

eff

icie

nt

of

Fric

tio

n

Temperature (ᵒC)

Effect of Temperature on Coefficient of Friction 15 N / 10 Hz

Oil-A

Oil-B

0.073

0.086

0.073

0.077

0.086

0.05

0.06

0.07

0.08

0.09

0.1

27 65 90

Co

effi

cien

t o

f Fr

icti

on

Temperature (ᵒC)

Effect of Temperature on Coefficient of Friction 25 N / 10 Hz

Oil-A

Oil-B

0.095 0.095 0.096 0.092

0.1

0.05

0.063

0.076

0.089

0.102

27 65 90

Co

eff

icie

nt

of

Fric

tio

n

Temperature (ᵒC)

Effect of Temperature on Coefficient of Friction 15 N / 20 Hz

Oil-A

Oil-B

Friction Characteristics

• Wear Characteristics

1. Ball Wear

0.83

1.20

0.36 0.38

0.00

0.30

0.60

0.90

1.20

1.50

15 25

We

ar R

ate

(mm

³/N

m)

Load (N)

Load Vs. Wear Rate of Ball 27ᵒC /10 Hz

OIL-A

OIL-B

×10-7

0.86 0.87

0.21 0.22

0.00

0.30

0.60

0.90

1.20

1.50

15 25

We

ar R

ate

(mm

³/N

m)

Load (N)

Load Vs. Wear Rate of Ball 65ᵒC /10 Hz

OIL-A

OIL-B

• Plate Wear

2.82

4.79

1.36 1.81

0.00

1.00

2.00

3.00

4.00

5.00

6.00

15 25

We

ar R

ate

(mm

³/N

m)

Load (N)

Load Vs. Wear Rate of Plate 27ᵒC /10 Hz

OIL-A

OIL-B

2.21

3.53

0.56

1.45

0.00

1.00

2.00

3.00

4.00

5.00

15 25

Wea

r R

ate

(mm

³/N

m)

Load (N)

Load Vs. Wear Rate of Plate 65ᵒC /10 Hz

OIL-A

OIL-B

2. Radiation resistance of hydraulic fluid • Objective: • The main objectives of this test was

• To give a brief description of fluids and standard test methods for viscosity measurement.

• To measure the viscosities of the Radiated oil sample at different level of radiation.

• To compare the result of two different oil sample each radiated at five different levels of radiation.

• Sample Preparation

• Measurement of properties of ENKLO-68:

1. Density: Following graph gives the variation of density in g/cm3 for fresh as well as irradiated oil samples with respect to temperature in range of 15-100 °C (288°K to 373°K).

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

283 303 323 343 363 383

De

nsi

ty (

g/cm

³)

Temperature (°K)

Density Vs Temperature

0 Mrad (Fresh Oil)

5 MRad

25 MRad

50 MRad

100 MRad

300 MRad

2. Effect of Gamma Radiation on Kinematic Viscosity: Following graph gives the variation of Kinematic Viscosity in mm2/s (cST) for fresh as well as irradiated oil samples with respect to temperature in range of 15-100 °C (288°K to 373°K).

1.0

10.0

100.0

1000.0

283 303 323 343 363 383

Kin

em

atic

Vis

cosi

ty (

mm

2/s

)

Temperature (°K)

Kinematic viscosity Vs Temperature

0 MRad (Fresh Oil)

5 MRad

25 MRad

50 MRad

100 MRad

300 MRad

3. Effect of Gamma Radiation on Viscosity index:

50

60

70

80

90

100

110

0 50 100 150 200 250 300 350

Vis

cosi

ty in

de

x

Gamma Radiation Dose (MRad)

• Measurement of properties of POE-68 oil:

1. Density: Following graph gives the variation of density in g/cm3 for fresh as well as irradiated oil samples with respect to temperature in range of 15-100 °C (288°K to 373°K).

0.2

283 303 323 343 363 383

De

nsi

ty (

g/cm

³)

Temperature (K)

Fresh5 MRad25 MRad50 MRad100 MRad300 MRad

Fresh

Oil

Sampl

e

300

MRad

100

MRad

50

MRad

25

MRad

5

MRad

2. Effect of Gamma Radiation on Kinematic Viscosity: Following graph gives the variation of Kinematic Viscosity in mm2/s (cST) for fresh as well as irradiated oil samples with respect to temperature in range of 15-100 °C (288°K to 373°K).

5

50

500

270 290 310 330 350 370

Vis

cosi

ty m

m²/

s

Temperature °K

Viscosity Vs Temp Graph for POE oil

Fresh

5 MRad

25 MRad

50 MRad

100 MRad

300 MRad

3. Effect of Gamma Radiation on Viscosity index:

142

144

146

148

150

0 50 100 150 200 250 300

Vis

cosi

ty In

de

x

Gamma Radiation Dose (Mrad)

VI

4. Conclusion and Future Scope

1. Tribological Evaluation

• The tribological evaluation for qualifying hydraulic Oil-A and Oil-B has been done on sliding friction and wear machine TE-70. Friction and wear were the major candidate for qualifying the oils.

• As discussed in previous chapter, the friction characteristics of the two oils are almost same. The stribeck curve shows that both Oil-A and Oil-B have similar operating conditions in hydrodynamic regime.

• The wear characteristics shows that the wear rate of ball and plate under Oil-A lubrication is high as compared to Oil-B but the order of wear rate is very low for both oils and is of order 10-7, which is condition of mild wear. Hence it can be acceptable.

• Based on tribological experiment it can be concluded that both hydraulic oils are similar in tribological behaviour, Oil-A has the advantage of being fire resistant. There for Oil-B can be replaced by Oil-A if there is chances of fire hazard or the operating temperature is high.

2. Radiation Resistant

• There is approx. 5.92% decrease in the density of the ENKLO – 68 and 6.02% decrease in the

density of the POE – 68 from 15 to 100 °C

• The density of both ENKLO-68 and POE-68 oil has been found to be resistive to radiation

levels up to 300 MRad for same temperature as the radiation level increases Density is not

much affected.

• The viscosity of the ENKLO-68 has been found to be more resistive to radiation levels and is

affected by 12-13% only where as POE-68 oil has been found to be less resistive and is

affected by 50-60% for same temperature.

• It is found that the percentage change in viscosity for both oil samples is higher in lower

temperature range as compared to that in higher temperature range with respect to un-

irradiated fresh oil sample.

• The viscosity index of the ENKLO-68 oil has not improved because of radiation and remains

constant, where as VI of POE-68 oil has improved.

• The appearance of hydraulic oil ENKLO-68 has changed after exposure to Gamma radiation,

where as the appearance of hydraulic oil POE-68 Remains unchanged.

• Analysis of Total Acid Number (TAN) and Total Base Number (TBN) may give the change in

acidic or basic content in the oil. This may be helpful to decide the effect of irradiated oil on

the components of hydraulic system.

• Based on above discussion it is concluded that up to 50 MRad radiation level Oil-A can be used as hydraulic fluid in replacement of Oil-B in nuclear industry when the operating temperature is high.

Future Scope • The test procedure discussed in this report for sliding friction and wear measurement can be

used for general purpose friction and wear test under lubricated or dry condition.

• The data available in this report can be used for selection of hydraulic oils for other applications also.

• The properties of hydraulic oils will required to be evaluated at more radiation levels, for this purpose it is planned to irradiate hydraulic oils at 5, 25, 100, 200, 300, 400 and 600 MRad radiation levels.

• The appearance of oil is not a major concern in this report but in future the oil has to be further analysed for presence of oxidation compounds using TAN and Oxidation Stability test.

• Change-over of a system from one hydraulic oil to another can create problems unless consideration is given to circuit and component design.

• For this purpose, a Fire Resistant Hydraulic Fluid Test Facility (FRHTF) will be developed by RTD at Engineering Hall – 3. In this facility hydraulic performance, compatibility with existing hydraulic components, and high temperature operability will be tested by evaluating the changes in properties of the hydraulic oils after being used in this facility test setups.

• The test facility will be designed to be operated without any operator.

• A man machine interface (MMI) will be required to design to run this test facility 24x7 without any operator assistance.

References 1. ‘Engineering Design Handbook of Hydraulic Fluids, Headquarters’, U.S. Army Materiel Command, April 1971. 2. W.D. Phillips, ‘A Comparison of Fire-resistant Hydraulic Fluids for Hazardous Industrial Environments. Part 1. Fire resistance and lubrication properties’,

FMC Corporation (UK) Ltd. 3. Sullivan, M.V., Wolfe, J.K., and Zisman, W.A., ‘Flammability of the higher boiling liquids and their “mists”’, Zng. Eng. Chem., 39, 12 (1947), 1607-14. 4. Murphy, C.M., and Zisman, W.A., ‘Synthetic hydraulic fluids’, Product Engineering, 21, 9 (1950), 109-13. 5. ‘Lubricants, Industrial Oils and Related Products – (Class L) – Classification – Part 4: Family H (Hydraulic Systems)’, ISO Standard 6743. 6. Santosh Javalagi and Swaroop Reddy Singireddy, ‘Hydraulic fluid properties and its influence on system performance’, Linköping University. 7. ‘Hydraulic Fluid Power – Fire-Resistant (Fr) Fluids – Guidelines for Use’, Bureau of Indian Standards, New Delhi-110002. 8. ‘Friction, Wear, and Lubrication: Terms and Definitions’, Research Group on Wear of Engineering Materials, Organization for Economic Cooperation

and Development. 9. H. H. Zuidema, ‘The Performance of Lubricating Oil’, Reinhold Publishing Corp., N. Y., 1959. 10. Federal Test Method Standard No. 791a, Test Method No. 6505. 11. Federal Test Method Standard No. 791a, Test Method No. 3807. 12. Federal Test Method Standard No. 791a, Test Method No. 3812. 13. ASTM Standards 1969, Designation D-2596- 67T, Part 17, p. 970, Philadelphia, American Society for Testing Materials, 1969. 14. Federal Test Method Standard No. 791a, Test Method No. 6514. 15. ASTM Standards 1967, Designation D-2266- 64T, Part 17, p. 799, Philadelphia, American Society for Testing Materials, 1967. 16. Federal Test Method Standard No. 791a, Test Method No. 6501. 17. H. Gisser, ‘The Effects of Nuclear Radiation in Lubricants’, Conference on Effects of Nuclear Radiation on Materials, Watertown Arsenal, 1967. 18. R. C. Gunderson and A. W. Hart, ‘Synthetic Lubricants’, Reinhold Publishing Corp., N.Y., 1962. 19. Roger E. Hatton, Introduction to Hydraulic Fluids, Reinhold Publishing Corp., N. Y., 1962. 20. Charles Spar, Hydraulic Fluids and Their Applications, ASME Publication 64 WA/LUB-14. 21. R.O .Bolt and J.G. Carrol, ‘Effect of radiation on aircraft lubrications and fuels’, California Research Corporation, WADC Technical Report No 56- 646,

Part II, ASTIA Document No. AD 151176. April 1958. 22. William L. R. Rice, ‘Nuclear Radiation Resistant Lubricants’, California Research Corporation, WADC Technical Report No 57-299, ASTIA Document No.

AD 118329 May 1957. 23. S. Sharma, S. Sangal, K. Mondal, ’ On the optical microscopic method for the determination of ball-on-flat surface linearly reciprocating sliding wear

volume’, Wear 300 (2013) 82–89 24. ASTM G133-05(2010), ‘Standard Test Method for Linearly Reciprocating Ball-on-Flat Sliding Wear’, ASTM International, West Conshohocken, PA,

2010, www.astm.org 25. Zeeshan Ahmad, P.K.Mishra, ‘Determination of Effect of Gamma Radiation on Petroleum based Hydraulic Fluid - ENKLO-68’ RTD Report, BARC,

Mumbai 26. http://www.viscopedia.com/methods/measuring-principles/ 27. Hutchings, I.M. (1992), ‘Tribology — Friction and Wear of Engineering Materials’, Edward Arnold, London. 28. Zum Gahr, K.-H. (1987), ‘Microstructure and Wear of Materials’, Tribology Series 10, Elsevier, Amsterdam.