CONVERTING TO PHOSPHATE ESTERS IS EASY!
Regardless of the type of hydraulic fluid being used, converting a system to phosphate esters is easy. Virtually every type of equipment that uses fire resistant
hydraulic fluid has been converted to phosphate esters.
If changing seals is necessary, equipment manufacturers can recommend what seals to change, and many carry a supply of correct seals.
This bulletin describes procedures and supplies required to replace conventional
fluids in hydraulic systems with Fyrquel fire-resistant fluids. For the most part, the
conversion involves draining the system, disassembling as needed, cleaning parts
and interior, removing paint from inside surfaces, inspecting parts for wear, reassembling with suitable packing and other materials, and servicing with Fyrquel
fluids, followed by minor adjustments and inspection after clean-up.
Conversion Procedures
The following conversion measures apply to all hydraulic systems, regardless of what
fluid has been used previously.
1. Drain system completely. Blow out pipes, lines, valves, reservoirs, pumps, and
accumulators, or clean them by hand as thoroughly as possible. Any fluid not removed may impair the performance or fire-resistant characteristics of the
Fyrquel (see special note A below)
2. Inspect interior surfaces for paint and remove it by using paint remover or by
scraping it off, because Fyrquel will dissolve or loosen most paints. Such paint,
grit, and other accumulations may damage pumps and valves if not eliminated. Apply a Fyrquel resistant paint if desired (see special note B below).
3. Clean suction strainers (see special note C below); if inspection reveals them to
have a size finer than 60 mesh, substitute a size 50 to 60 mesh, as Fyrquel has a
fairly high specific gravity which makes suction flow more critical. Replace pressure system cellulosic filter cartridges with new refills that are rated
compatible with phosphate ester fluids.
4. Check all components for wear, scouring, or corrosion and replace if necessary.
Lubricate the parts with Fyrquel fluids before assembly to avoid dry start-up.
5. Gaskets, packings, and seals that are resistant to Fyrquel fluid should be used.
These include elastomers such as Viton, ethylene-propylene rubber, butyl rubber,
silicone, Teflon, or equivalent compounds. Be sure to use such materials for moving or dynamic seals, because other substances may swell in the presence
of Fyrquel and impair the free operation of moving parts or cause loss of fluid.
Unless static joints are dissembled, the replacement of static seals is optional
because swelling in this case will only produce a tighter connection. Refer to “Phosphate Ester Compatibility Guide” for proper material replacements.
6. Use a butyl rubber-lined, high –pressure hose for best results with Fyrquel.
However, if necessary standard high-pressure hose can be used temporarily when sizing is adequate to compensate for internal swelling.
7. Replace bladders used in accumulators with ones made of butyl, Viton, or E-P rubber; that is essential. Metal piston accumulators require no conversion unless
internally painted or rubber O-rings are used. Paint should be removed and/or O-ring replaced with compatible ones.
8. Flush the system with Fyrquel flushing charge after assembly for best
performance. Remove solid contaminants from the flush fluid by simple filtration
through a cellulosic filter before using the fluid to clean other machines.
9. Install Fyrquel of the viscosity recommended by the equipment maker.
10. Avoid pump cavitation by providing sufficient flow at the pump inlet, by providing
adequate strainer capacity and diameter of inlet line. A vacuum gauge may be installed near the inlet port as a safety precaution. Readings of more than five
inches of mercury indicate the need to increase size of inlet line. If the latter step
does not reduce the vacuum reading enough, consider reducing pump speed, decreasing the vertical distance between the fluid level and the pump, or
increasing the capacity of strainers.
11. Follow regular start-up procedure after system is reassembled and filled with new
Fyrquel.
12. Inspect the system carefully in operation for leaks at seals and joints. Inspect
filters and strainers frequently after start-up to avoid clogging by foreign matter
that may possibly have remained in the system. Recheck fluid level after machine is returned to production.
13. In service monitoring is important with fire resistant hydraulic fluids.
Oiltech Australia provides Techcheck Condition Monitoring services which many users found useful as an adjunct to their predictive maintenance system. Be sure
to contact us for more information.
Special Notes on Conversion
A. Aqueous base fluids are incompatible with Fyrquel and should be flushed out with
hot water or steam or cleaned out manually. Flush water should be blown out and low points drained. Seals, paints, and packings should be changed as
outlined above.
After the machine is filled with Fyrquel and operating, it should be inspected to
see if there is any residual water on top of the Fyrquel in the reservoir; if so, the
water should be siphoned off or decanted.
In service monitoring using Oiltech Techcheck Condition Monitoring program will ensure trouble free operation and peace of mind.
B. Because Fyrquel is relatively non-corrosive towards materials of construction
commonly used in industrial hydraulic equipment, interior surfaces need not usually be painted. In some cases, however, the presence of moisture , as in the
open space of a reservoir, may indicate need for a Fyrquel resistant paint.
C. Most hydraulic systems contain filters; these become more important when
Fyrquel is used, since the latter loosen many paints and residues that may have
been formed by the fluid used previously. Even if no permanent filter is provided,
a filter such as a portable one should be used in the system for a few days. An oil
screen of 50 to 60 mesh, or a suitable filter cartridge of the cellulose type, is
recommended. Filtration will not alter the properties of Fyrquel, and most types of
filters will operate satisfactorily with Fyrquel.