Technical Topic
Fire Resistant Fluids
In Power Generation
The importance of fluid selection and maintenance is never more
apparent than on the Electro Hydraulic Controls (EHC) that are
responsible for governing steam supply to turbine generators.
High pressures and temperatures dictate the use of fire resistant
fluids to mitigate the potential for dangerous and expensive fires.
Phosphate esters are the most common fluid used in EHC
systems in power turbine control systems. Phosphate esters
used in EHC systems require special care and maintenance
compared to mineral oils.
Gas turbines, designed to supply power during periods of
What is a Fire Resistant Fluid? peak demand, require fast start up without problems
Fire resistant hydraulic fluids are specially formulated lubricants
that are more difficult to ignite and do not propagate a flame In addition to these tests, Factory Mutual has developed the Spray
from an ignition source. Fire resistant should not be confused Flammability Parameter and European Economic Community
with fire proof, as fire resistant fluids will still ignite and burn through the 7th Luxembourg Report developed the “stabilized
given specific conditions. flame heat release” otherwise known as the “Buxton Test”. Both
of these standards use spray ignition tests and calculations for
There are several types of fire resistant fluids and they are generally
heat rate. Detailed descriptions of these tests go beyond the
classified as follows:
scope of this article.
• Oil and water emulsions
• Water glycols Care of EHC Fluids
• Anhydrous synthetics The most commonly used fluids for EHC systems are HFDR
(phosphate ester type). Triaryl phosphates are most commonly
More specifically, the International Standards Organization (ISO)
used in EHC systems.
further classifies these fluids as follows:
• HFAE – oil in water emulsions having no more than HFDR fluids require special care and maintenance in service,
20 percent emulsifying oil especially in EHC systems. Water content, resistivity, acid content,
• HFAS – synthetic aqueous fluids chlorine content, mineral oil content, metals and cleanliness all
• HFB – water in oil emulsions typically containing 60 percent oil need to be monitored and maintained for optimum performance
in the system.
• HFC – aqueous solutions of glycol and polyalkylene glycol
thickener in water
Phosphate esters are hygroscopic (have a natural affinity to
• HFDR – anhydrous fluids composed of phosphate esters
absorb water) but also have poor hydrolytic stability (i.e. the fluid
• HFDU – synthetic anhydrous fluids other than phosphate can degrade in the presence of water). In the presence of water,
esters. Examples include polyol esters and polyalkalene glycols.
phosphate esters undergo hydrolysis reactions, which can lead to
increasing acidity, system corrosion and/or erosion of sensitive
Evaluation of Flammability
components. As such, water content and Total Acid Number
The fire resistance of a fluid is generally measured in one of
(TAN) should be closely monitored on a regular basis.
three ways:
• Ignition of a pressurized fluid spray (spray flammability test) Where servo valves are used, a high fluid resistivity (or low
• Ignition of a fluid when sprayed on a hot surface (hot conductivity) is necessary to avoid electromechanical erosion of
surface ignition test) the valve spool. Low resistivity is usually found when the fluid
• Ignition of a fluid that has impregnated porous or wick type has become acidic through hydrolysis, or is contaminated with
materials (fluid evaporation test) chlorine compounds or other particulates.
Very small amounts of chlorine (particularly in the form of Fluid Condition Monitoring
chloride ions) can cause servo valve erosion problems. Chlorine A rigorous fluid condition monitoring program is essential to
contamination can result from the use of chlorinated solvents, maintain long trouble-free operation. A suggested schedule of
from cooling system leaks and chlorides absorbed from the air fluid analysis tests follows:
when the system is near the sea.
• Viscosity at 40°C – ASTM D445
• Water Content – ASTM D6304
Mineral oil content must also be controlled. Excess mineral oil
contamination (> 0.5 percent) can adversely affect foaming and air • Mineral Oil Content – (Chromatography or IR Spectroscopy)
release properties. Higher quantities (> 4 percent) will reduce the • Flash Point – ASTM D92
fire resistance and oxidation stability. • Auto-ignition temperature – ASTM D2155
• TAN – ASTM D664
Minimizing particulate contamination is important at all times when • Volume Resistivity – ASTM D1169
fine tolerance servo valves are used. Servo valves are particularly
• Cleanliness (ISO Particle Count 4406)
sensitive to abrasive wear and erosion from particulates; leading
• Foaming Tendency – ASTM D892
to loss of system sensitivity and control. Particulate contamination
may also impact the resistivity of the fluid causing further erosion • Air Release Properties – ASTM D3427
of the valve components. • Metals – ASTM D5185
TAN, water content, particulate contamination (particle count) and
Phosphate Ester Fluid Conditioning
volume resistivity are recommended to be monitored on a monthly
In order to maintain suitable fluid condition, special conditioning
basis. Other properties are typically monitored on a quarterly or
methods are used. With phosphate esters this is normally
semi-annual basis.
achieved with an adsorbent solid filter such as Fuller’s earth or
activated alumina in combination with vacuum dehydrators and Material Compatibility
standard particulate filters. Special considerations must be taken with phosphate esters
regarding material compatibilities. Phosphate esters will soften
The Fuller’s earth or activated alumina is used to strip acids and some paints requiring the use of selected epoxy based paints
chlorides from the fluid to maintain a low fluid acid number level. or leaving the reservoir unpainted. Phosphate esters are not
Typically, the acid number should be maintained below 0.2 compatible with the standard nitrile rubber seals typically used
mgKOH/g and chlorine content should be maintained below 100 in mineral oil systems and require the use of specialized seal
ppm. Also, calcium, magnesium and sodium levels should be materials. Additionally, care should be taken when mixing
monitored. Excess amounts of these materials may be an indication phosphate esters from different suppliers. In general, phosphate
that the adsorbent filters need to be replaced. More recently, Ion esters are compatible with other phosphate esters, however
Charge Bonding (ICB) filters are being used that avoid metal the equipment manufacturer and/or fluid supplier should be
leaching from adsorbent filters. contacted about specific compatibility issues.
Vacuum dehydrators can be used to maintain a low water content Reference:
as well as assist in the removal of entrained air in the fluid. Water
• “Current Standards for Certification of Fire Resistant Hydraulic
content should generally be held below 0.15 percent or 1,500 ppm.
Fluids Used in General Industrial Applications”, Fluid Power
Journal Jan/Feb 2006 pp. 30-36.
Particulate filters can be used to reduce and maintain the particulate
level in an oil. The cleanliness is reported according to the ISO • “Managing the Health of Fire Resistant Steam Turbine Electro
cleanliness classification (ISO 4406) of the fluid. Typically, 2 hydraulic (EHC) EHC Control Oils”, Machinery Lubrication
micron, beta > 75 filters are required to prevent particulates 2006
from damaging or blocking servo valve components. An ISO • Reolube Turbofluids Guide to their maintenance and use,
Cleanliness code of 18/16/13 or lower should be targeted. Great Lakes Chemical Corporation Publication
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