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pyprauL MonsantoAIR COMPRESSOR LUBRICANTS BY 0068<i28 TOWOLDMONOQ21669 Contents PAGE 1 The Pydraul Air Compressor Fact Finder 1 How Compressor Fires and Explosions Occur 3 Pydraul Fire-Resistance 4 Pydraul AC-A Virtually Eliminates Valve Deposits 5 Converting To Pydraul Is Easy 6 Pydraul Provides Excellent Lubricating Qualities 7 Mixing Compatability 7 Pydraul Is Used As A Lubricant For Compressors Made By All Major Manufacturers 8 Safe Handling TOWOLDMONOQ21670 The Rydraul Air Compressor Fact Finder . . . Is designed to make the many facts about Pydraul tire resistant lubricants for air compres sors--Pydraul AC-A, Pydraul AC-A Winter Grade 28 and Pydraul 625A--easy to find. These safety lubricants for air compressors were specially developed to offer you: Safety from Fire and Explosion Pydraul eliminates combustible mists and mini mizes carbonaceous residues -- greatly reducing the threat of compressor fires and explosions. Lower Maintenance Costs Pydraul eliminates deposits on exhaust valves, in coolers and in piping. You save the costs of com pressor downtime and cleaning. Many compressor users find these savings alone justify using Py draul lubricants. How Compressor Fires & Explosions Occur Every theory about the mechanisms of compres sor fires and explosions hold one idea in common: petroleum oils are directly involved. Petroleum Oil Mists & Films Mist and accumulated films from petroleum oil in compressor systems can, under a variety of con ditions, break down into combustible gases and carbonaceous residues that can ignite and pro duce an explosion, a receiver fire--or both. The U. S. Bureau of Mines' found that carbon deposits in air compressors lubricated with petroleum oil form a "carbon-oxygen complex." Oxidation forms this complex, and accelerated by heat, this oxida tion process can lead to an explosion. The Shortcomings of Safety Devices Safety devices do not completely eliminate fire and explosion possibilities. A study on "The Mecha nism of Explosions In Starting Air Lines,"2 based on an exhaustive survey of compressor operations at 53 companies, reports that a stuck or leaking air check valve permits the engine being started to pack the section of line between the check and air timing valve with an explosive "oil residue-air" mixture. A pressure wave will force this mixture upstream into the main air line--and coupling this with good flame propagation in the power cylinder, the condition is laid for explosion in the pipe sys tem. Air line explosions and fires may even occur with out the engine being started or before the ignition is turned on. Carbon and rust particles in a "hot" air line, due to operating an overheated compres sor too long--hardly an improbable condition-- can become saturated with oil, and with the flow of starting air, can cause these oil-saturated par ticles to flame. Explosion Tests at 1300 PSI The Walter Kidde Company, makers of fire extin guishing equipment, warns in a study" that users of high pressure air should guard against intro ducing a shock wave into high pressure lines by suddenly opening a plug cock in air compressor systems using petroleum oil. This report showed that in a 1-inch diameter tube, the inside walls filmed with oil, a sudden admission of air at pres sures above 1300 psi caused combustion. How can you eliminate the conditions that cause fires and explosions in air compressors? Eliminate the source of carbon deposits, the basic cause of most air compressor disasters--petroleum oil. Substitute fire- and explosion-resistant Pydraul. 1. "The Carbon-Oxygen Complex as a Possible Initiator of Explosions and Formation of Carbon Monoxide In Com pressed Air Systems," by Busch, Berger, and Schrenk, Bureau of Mines paper R.1.4465, June 1949. 2. "The Mechanism of Explosions In Starting Air Lines," by Ridgway, Robert S., Petroleum Reliner, June 1958. 3. "Oil Combustion Phenomena in High Pressure Air Sys tems," M. W. Weibel, Walter Kidde & Co., Inc., Report R-831, copyright 1952. 1 0068430 TOWOLDMONOQ21671 COMPATIBILITY WITH METALS pydraul air compressor lubricants are compatible with all construction metals Including aluminum. In most operations, aluminum bearing surfaces will wear as long as any other metal surfaces lubri cated with Pydraul If they have been anodized. TABLE 2--VAPOR PRESSURE Temporature Vapor Pressure mm Hg C. *F. PYDRAUL AC-A PYDRAUL 625A PYDRAUL AC-A WINTER GRADE 28 0 10 20 40 60 80 100 150 200 32 50 68 104 140 176 212 30? 392 3.5 x 10-6 n.ox 10-6 3.3 x 10-5 2.4 x 10-4 11.5 x 10-4 5.0 x 10-3 1.7 x 10 ? 0.26 2.2 0.30 x 10-6 1.1 x 10-6 4.0 x 10-6 3.8 x 10-5 2.3 x 10-4 1.2 x 10-3 0.55 x 10? 0.13 1.4 5.5 x 10-617.5 x 10-6 50 x 10-6 3.5 x 10-4 1.6 x 10-3 6.6 x 10-3 2.2 x 10? 0.31 2.3 Vapor Density. 11.2 compared to value for air of one (1). PYDRAUL AC-A PYDRAUL AC-A WINTER GRADE 28 Clear Blue liquid 1785-1.325 0,15 " 0.15%' ' 85 to 95 5.9 to 6.3 417.0 SSU 46.2 SSU 545 SSU 60 SSU +57. ....MO.... 3507. ~ m7" 0.00045 ...... 0.31....... 0 064 " ~ 400,000 ` 45.0 Negligible' Clear Blue Liquid [ 1.235-1.255 0.15 . 0.15% 26 to 30 3.8 to 4.2 132.8 SSU 39.3 SSU 165 SSU 45 SSU --257. 3507. 8107. 0.00041 0.33 0.068 380,000 41.0 Negligible FIGURE 1--TYPICAL VISCOSITIES _ PYDRAUL 625 A ____ PYDRAUL AC-A ____ PYDRAUL AC-A WINTER GRADE 28 TOWOLDMONOQ21672 Pydraul Fire-Resistance Pydraul fire-resistant fluids and lubricants have worked in industry since 1951, providing many millions of machine hours of fire-free operation. Never during these hours of machine operation has a Pydraul fluid contributed to a fire- and never since their introduction in 1954 has any Pydraul fire-resistant compressor lubricant caused a compressor fire or explosion. FIRE-RESISTANCE TESTS OF PYDRAUL AC-A, PYDRAUL AC-A WINTER GRADE AND PYDRAUL 625A TEST High Pressure Spray Test AMS3150C and Federal Test Method Std. 791. Test fluid sprayed at 1000 psi through orifice, passing through flame of oxyacetylene torch, 6000F. RESULTS Does not flash or Ig nite up to 3V2 feet from orifice. Atomized Spray Test (procedure used by Factory Mutual Engineer ing Division). Test fluid heated to 140F. sprayed at 1000 psi from atomized cone type nozzle. A torch is passed through this spray 2 feet and 2 to 6 Inches from the orifice. Local burning by torch at 6 inches and 2 feet from orifice. Flames self-extinguishc imme diately when torch re moved. Hot Manifold Test (Federal Test Method Std. 791). Test fluid drip ped on tube at 1300F. Does not flash or burn. Molten Meta! Ignition Test. Test fluid exposed to the surface of aluminum alloy at 1200oF., to test for spontaneous Ignition. Does not ignite. 0068*32 TOWOLDMONOQ21673 500 hours on premium petroleum oil 500 hours on Pydraul AC-A Pydraul AC-A Virtually Eliminates Valve Deposits Compressor Data: 142 CFM, 6" LP Bore, 5" HP Bore, 5" Stroke, 870 RPM, 100 psi air The photos compare exhaust valve deposits formed during individual 500-hour operations on two lubricants: a premium grade petroleum oil . . . and Pydraul AC-A*. A glance at the photo of the valve lubricated with petroleum oil shows considerable carbon deposit build-up after 500 hours operation. The improve ment in the valve condition in the photo on the right is obvious- virtually no carbon deposits after 500 hours operation with Pydraul AC-A. In the par ticular case, the compressor operator expects to get 7500 to 10,000 hours of service from Pydraul AC-A without shutting down- a 15- to 20-fold in crease in operating time without a shutdown. Re sult: substantial maintenance savings in time and money--and virtual elimination of the fuel source of most air compressor fires and explosions. *No photographs available of Pydraul 625A and Pydraul AC-A Winter Grade 28, but results are at least Identical. 0068433 TOWOLDMONOQ21674 Is Easy ['iisl, simply drain the petroleum oil and wipe the oMnkcaso or lubricator. Thoroughly clean the exhaust valves and interil.igc equipment before filling the crankcase or lubikalor with Pydraul. Pydraul will loosen car bonaceous deposits, varnishes and sludge. Unless these loosened deposits are cleaned from the sys tem, they could clog pipelines and components, icquiiiny additional downtime and production loss. Once the valves have been thoroughly cleaned of potentially dangerous carbon deposits, Pydraul lubricants will keep them clean- and let compres sors run longer between maintenance shutdowns. S IANUARD CHECK FOR COMPRESSORS--Plaslic separator bowls. Not all plastic separator bowls are suitable for rydiaul service. Certain plastics are "crazed" or s oftened when exposed to Pydraul. Bowls made of glass, biass, steel, and these plastics---polycar bonate, polyethylene, or nylon- are recommended for use with Pydraul. If you have a question regaiding the resistance of a particular plastic, Men;,auto will be happy to advise you. Pi, plm.gin valves. Pydraul lubricants have a sof tening ellect on neoprene and buna N rubber diaphragms normally used for petroleum oil serv ices These diaphragms should be replaced with butyl mbber, EPR (ethylene propylene rubber), (luoiuulastomor, silicone or other compatible elastoinei materials resistant to Pydraul fluids. Diapluagm sheeting is available from normal sources of supply. All diaphragms in unloading valves or downstream sontiol valves should be replaced at the time of changeover. Diaphragms in valving downstream hem separator systems or drying systems need not be loplaccd at changeover time, but should be changed on a preventative maintenance schedule as soon as practicable after operation on Pydraul is begun, Toi aii compressors supplying air for instrumenta tion functions, mist eliminator systems are recom mended to remove lubricant mists and moisture hem air streams. A Monsanto development, a Hiink'' mist eliminator is a particularly effective system, available from Monsanto in a series ot lowcosi mist eliminator systems to operate at all ca pacities. For information on a Brink series suitable for your compressor system, write to: Monsanto Envlro-Chem Systems, Inc. 800 North Lindbergh Blvd. St. Louis, Mo. 63166 Telephone: (314) 694-2286 (Joseph A. Brink) SPECIAL CHECK FOR SPLASH-LUBRICATED COMPRESSORS Crankcase paint. Pydraul air compressor lubri cants will soften and loosen some paints from crankcase interiors. These paint particles could block the lubricant passages. For this reason, it is a good practice to remove paint from crankcase interiors before Pydraul is added to the system. Standard paint removers are adequate for remov ing this paint. . SPECIAL CHECK FOR FORCE-FEED LUBRICATORS Sight-glass fluid. If a separate force-feed lubri cator of the type normally filled with water and glycerine is used, one of two changes is neces sary: either replace the sight-glass fluid with one heavier than Pydraul or insert a metal bobber in the sight-glass. Pydraul fluids are heavier than water or glycerine and will not rise through these standard sight-glass liquids. Fluorochemical 101, a clear liquid supplied by the Minnesota Mining and Manufacturing Company, has a higher density than Pydraul and is a completely satisfactory re placement. Metal bobbers. The alternate to using FIuorochemical 101 is to modify the sight-glass lubricator by inserting a simple metal bobber. The bobber is installed by draining the sight-glass liquid, remov ing the guide wire and inserting the bobber. Operation of the lubricator is then indicated by movement of the bobber with each stroke of the pump plunger instead of counting the drops as with guide wires. Bobbers are available for either McCord, Manzell, or Lincoln Engineering lubri cators. Modification of the Madison-Kipp lubricator requires replacement of the entire sight-glass. Vacuum-sight lubricators. Vacuum-sight lubrica tors require no modification tor Pydraul usage. 0068434 TOWOLDMONOQ21675 Pydraul Provides Excellent Lubricating Qualities TABLE 3 FALEX LOAD TEST PASSING LOAD Pydraul 625A Pydraul AC-A Pydraul AC-A Winter Grade 28 4250 4025 4175 TABLE 4 FALEX WEAR TEST WT. LOSS, PIN (mg.) WT. LOSS, BLOCKS (mg.) Pydraul 625A 1.1 5.8 Pydraul AC-A 0 0.5 Pydraul AC*A Winter Grade 28 0.6 0.9 TABLE 5 TIMKEN OK LOAD (lbs.) FILM STRENGTH (psl) Pydraul 625A Pydraul AC-A Pydraul AC-A Winter Grade 28 30 11,700 45 15,100 24 8,600 TABLE 6 SHELL FOUR-BALL WEAR (167"F., 1 hour, 630 rpm., mm scar diameter) STEEL ON STEEL PYDRAUL 625A PYDRAUL AC-A PYDRAUL AC-A WINTER GRADE 28 10 kg 40 kg STEEL ON BRONZE 10 kg 0.23 0.60 0.46 0.33 0.67 0.48 0.42 0.66 0.43 i\ DROP SIZE Drop size of a lubricant is important to determine an adequate lubricant injection rate to insure proper compressor lubrication. The rate of lubri cation is controlled by noting the drops per unit of time. The drop size for the fluids tabulated below were determined by noting the number of drops formed at room temperature (75F.) on a 1 mm I.D. by 3'/2 mm O.D. glass tip. (Larger or smaller drops will result if different sized tips are used.) Fluid Medium weight petroleum oil Pydraul AC-A Drops per cubic centimeter 33 39 When installing new equipment, it is best to start with an increased lubricant feed rate and reduce this rate by successive increments. Inspection of cylinder walls and valves will indicate the proper degree of wetting. 0068435 TOWOLDMONOQ21676 Mixing Compatibility Pydraul AC-A, Pydraul AC-A Winter Grade 28 and Pydraul 625A are completely miscible in all pro portions with competitive synthetic phosphate estor lubricants. Pydraul Is Used As A Lubricant For Air Compressors Made By All Major Manufacturers New air compressors of most types and sizes pro duced by major compressor manufacturers can be manufactured for lubrication with Pydraul. The manufacturers listed (below) have manufactured compressors equipped for Pydraul, upon specifi cation of the buyer, for over ten years. Many com pressors have operated on Pydraul lubricants con tinually with exhaust air temperatures of 350F. Pydraul Is also used to lubricate cylinders in com pressors operating at pressures over 4500 psig. American Messer Corporation Atlas Copco Bury Compressor Company Carrier Corporation Chicago Pneumatic Tool Company Clark Brothers Company, division of Dresser Industries Cooper-Bessemer Corporation DeLaval Steam Turbine Company Gardner-Denver Company Ingersoll-Rand Company Joy Manufacturing Company Kinney Manufacturing, division of The New York Air Brake Company Norwalk Company, Incorporated Schramm, Incorporated Worthington Corporation 0068436 TOWOLDMONOQ21677 Safe Handling There has been no reported case in many years of service to indicate any special health hazard with Pydraul air compressor lubricants. However, as with all specialized industrial fluids and lubricants, certain precautions are advisable. Animal toxicity screening studies indicate Pydraul AC-A, Pydraul AC-A Winter Grade 28 and Pydraul 625A may be considered only slightly toxic from the standpoint of accidental ingestion or skin ab sorption. It does not appear to have any signifi cant potential for skin or eye irritation. Because these fluids have excellent solvent properties, re peated or prolonged skin contact could lead to de fatting and drying of the skin; thus reasonable personal hygiene practices are recommended to avoid prolonged and repeated skin exposure. If Pydraul fluids are splashed or sprayed into the eyes, moderately severe pain and irritation may result. There Is no evidence to show Pydraul causes permanent eye tissue damage. Eyes should be thoroughly flushed with water and the workman referred to a physician. To relieve irritation, physi cians have used 1% pontocaine solution, as well as the ophthalmic cortisone acetate solution. Vapor inhalation. At room temperatures, there is no vapor inhalation hazard from Pydraul fluids. Although there has been no problem with high concentration of vapors, inhalation of vapors at high temperatures should be prevented. If the compressed air is to be used for air line masks, respirators and other inhalation equipment, it is always recommended that a commercial filter cartridge for air-supplied masks be incorporated in the compressor air line to remove any foreign matter. This is good industrial practice for any compressor fluid or lubricant. 0068A37 | TOWOLDMONOQ21678 DISTRICT SALES OFFICES ALL DIVISIONS AKRON, OHIO 44313 260 Spiingside Drive Montrose Development Park let. (216) 666-4111 ATLANTA, GEORGIA 30326 Lenox Towers East 3400 Peachtree Rd. N. E. -- Suite 1711 Tel. (404) 577-2260 . . BOSTON, MASSACHUSETTS 02149 Everett Station Tel. (617) 387-5010 CHICAGO, ILLINOIS 3158 Des Plaines Ave. Des Plaines, Illinois 60018 Tel. (312) 296-6688 CINCINNATI, OHIO 45206 1501 Madison Road Tel. 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(212) 556-5100 0066438 TOWOLDMONOQ21679 0068*39 Monsanto "Nothing contained herein is to be constiued as a recommendation to use any product in conflict with any patent M0NSAN10 MAKES NO WARRANTIES AS TO T HE f II Nl SS OR MERCHANTABILITY OF ANY PRODUCTS REFERNID TO. no guarantee ol sabslactory results horn reliance upon contained mlcumation pi recommendations, and disclaims at! haMrly tot any resulting loss or damage " Monsanto Company / Functional Fluids / 800 North Lindbergh Blvd. / St. Louis, Missouri 63166 0770-161-LRA litlio in U. S, A. TOWOLDMONOQ21680