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correction copy Fire Resistant Lubricants For Air Compressors CONTENTS Page 1. Introduction Page 2. Compressor Fires & Explosions Page 3. Table 1, Physical Properties and Viscosity Table 2, Vapor Pressure Page 4. Figure 1, Specific Heat Figure 2, Specific Gravity Plot Figure 3, Typical Viscosities Page 5. Pydraul Fire Resistance Page 6. Elimination of Valve Deposits Page 7. Converting to Pydraul Page 8. Lubrication Qualities Table 3, Film Strength Table 4, Wear Under Continuous Lead Table 5, Timken (Extreme Pressure) Table 6, Shelf Four-Ball Wear Table 7, Pump Test Page 10. Mixing Compatability Table 8, Pydraul with Other Hydraulic Fluids Page 10. Major Air Compressor Manufacturers Using Pydraul Page 12. Safe Handling 00>6Z*8 TOWOLDMON0021570 WATER_PCB-00006039 The PYDRAUL Air Compressor Fact Finder ... is designed to make the many facts and features about. Pydraul fire-resislant lubricants for air compressors quick and easy to find. We hope you will find it helpful in working with these safety lubricants for air compressors-- Pydraul AC, Pydraul AC Winter Grade 28, and Pydraul 625. Special safety lubricants for air compressors provide three important advantages over petroleum oil: safety from fire and explosion, virtual elimination of valve deposits, and lower maintenance costs. By eliminating combustible mists and minimizing carbonaceous residues, Pydraul lubricants reduce the threat of compressor fires and explosions. Pydraul lubricants also reduce compressor main tenance costs. By eliminating deposits on exhaust valves, in coolers, and in piping, these lubricants greatly reduce the costs of compressor down-time and cleaning. These lower maintenance costs alone usually justify using Pydraul lubricants for air compressors. For air compressors which operate in low ambient temperatures, Pydraul AC Winter Grade 28, a low temperature lubricant, is recommended. Pydraul 625 is recommended for compressors requiring a high viscosity lubricant. 0068229 II TOWOLDMON0021571 WATER_PCB-00006040 How Compressor Fires & Explosions May Occur There areseveral theories concerning the mechanisms of fires and explosions in air compressor systems, but one point, is common in every case: petroleum oil lubricants are directly involved. 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 produce an explosion, a receiver fire--or both. The U. S. Hurcau of Mines3 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 oxidation process can lead to an explosion. Safety devices do not completely eliminate fire and explosion possibilities. A recent study on "The Mechanism of Explosions In Starting Air Lines,"2 based on an exhaustive survey of compressor opera tions at 53 companies, reporta that a stuck or leak ing air check valve permits the engine being started to pack t he sect ion 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 system. Air line explosions and fires may even occur with out the engine being started or before the ignition is turned on.2 Carbon and rust particles in a "hot" air line, due to operating an overheated compressor too long--hardly an improbable condition--can be come saturated with oil, and with the flow of start ing air, can cause these oil-saturated particles to flame. The Walter Kidde Company, makers of fire ex tinguishing equipment, warns in a study3 that users of high pressure air should guard against introducing 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 pressures above 1300 psi caused combustion. The variety of fire and explosive conditions that may occur in air compressors lubricated with petro leum oil are many and unpredictable. This danger and unpredictability raises the need for eliminating the source of carbon deposits, the basic cause of most air compressor fires and explosions. Fire- and explosion-resistant Tydraul air compressor lubricants essentially eliminates this basic cause by minimizing carbon deposits. Their superior oxida tion resistance adds to their ability to prevent ex plosions. And by their inherent ability to resist burning in air, Pydraul lubricants substantially reduce the threat of fire. 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,1' by Ridgway, Robert S., Petroleum Refiner, June 1958. 3. "Oil Combustion Phenomena in High Pressure Air Systems," M. W. Weibel, Walter Kidde & Co., Inc., Report R-831, copyright 1952. 0068Z30 TOWOLDMON0021572 WATER_PCB-00006041 TABLE 1 PHYSICAL PROPERTIES Appearance Spec. Gravity 25Y?5C. Neutralisation No, (acidity) (mg K0H/gm)max. Moisture (max.) VISCOSITY Cenlistokes (?) 100F. 210F, Saybolts a$ lOOT. measured: 210F, "Absolute Saybolts" JOO'T. (SSU x Density) 210F. Pour Point Compressibility t Kb* sq. in./lb. Maximum Exit Air Temperature Boiling Point T. at 760 mm Hg. Coetlicient of Thermal Expansion per F. Specific Heat (BTU/lb./F.) ( 77CF.) Thermal Conductivity BTU/hr./ft./F. Vapor Pressure Hg 2O0F. Bulk Modulus /Room Temp.\ ^ 1000*6000 j Surface Tension Dynes/cm 25C. Solubility in Water * COMPATIBILITY WITH METALS PYDRAUL 625 Cloudy Blue Liquid 1.360-1.400 0.30 0.15% 125 to 145 5.7 to 6.2 625.7 SSU 45.9 SSU 845 SSU 59 SSU +30F. 2.66 350F. 724 T. 0.00040 0.28 0.065 0.09mm 375,000 40.2 Negligible PYDRAUL AC Clear Blue Liquid 1.345-1.385 0.15 0.15% 82 to 92 4.6 to 5.0 408.8 SSU 42.1 SSU 550 SSU 50 SSU +20F. 2.66 .350F. 688F. 0.00040 0.32 0.056 2.0x10-* 375,000 45.0 Negligible PYDRAUL AC WINTER GRADE 26 Clear Blue Liquid 1.275-1.295 0.15 0.15% 25 to 30 3.5 to 3.9 132.5 SSU 38.2 SSU 180 SSU 52 SSU 0F. 2.66 3506F, 688F. 0.00040 0.32 0.066 2.0x10-* 375,000 41.0 Negligible Pydraul air compressor lubricants are compatible with all con struction metals including aluminum. In most operations, alu minum bearing surfaces that have been anodized will wear as long as any other metal bearing lubricated with Pydraul lubri cants. - 0060231 TOWOLDMON0021573 WATER_PCB-00006042 FIGURE 2 SPECIFIC GRAVITY PLOT: Pydraul--Oil Mixtures at 60F. --PYDRAUL 625 --PYDRAUL AC ' ' PYDRAUL AC WINTER GRADE 28 TEMPERATURE, DEGREES FAHRENHEIT TO USE CHART... Obtain specific gravity of mixture, then read hori* rontally along specific gravity line to intersection of graph. Read down to composition of mixture (% Pydraul in italics). % Pydraul: 0 % Oil: 100 10 90 20 30 80 70 40 50 60 60 50 40 70 80 30 ` 20 90 100 10 0 FIGURE 3 TYPICAL VISCOSITIES PYDRAUL 625 PYDRAUL AC ' PYDRAUL AC WINTER GRADE 28 0068232 | TOWOLDMON0021574 WATER_PCB-00006043 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 its introduction in 1954 as a fireresistant compressor lubricant has Pydraul AC caused an air compressor fire. FIRE-RESISTANCE TESTS OF PYDRAUL AC TEST RESULTS* 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. Does not flash or ignite up to 3V4 feet from orifice. Low Pressure Spray Test (AMS3150C). Test fluid sprayed at low pressure over ignited, oil-soaked rag to determine degree of in crease in flame intensity. Very slight in crease in flame intensity. Hot Manifold Test (Federal Test Method Std. 791). Test fluid dripped on tube at 1300F. Does not flash or burn. Molten Metal Ignition Test. Test fluid exposed to the surface of aluminum alloy at 1200F., to test for spontaneous ignition. Does not ignite. 'Results are the same for Pydraul 625 and Pydraul AC Winter Grade 28. 0060133 5 TOWOLDMON0021575 WATER_PCB-00006044 PYDRAUL AC Virtually Eliminates Valve Deposits Compressor Data: 142 CFM, 6" LP Bore, 5" HP Bore, 5" Stroke, 870 RPM, 100 psi air 600 hours on premium petroleum oil 6 500 hours on Pydraul AC The photos compare exhaust valve deposits formed during individual 500-hour operations on two lubri cants: a premium grade petroleum oil . . . and Pydraul AC*. 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. In the particular case, the compressor operator expects to get 7500 to 10,000 hours of service from Pydraul AC without shutting down--a 15- to 20-fold in crease in operating time without a shutdown. Re sult: substantial maintenance Bavings in time and money--and virtual elimination of the fuel source of most air compressor fires and explosions. No photographs available of Pydraul 625 and Pydraul AC Winter Grade 28. but results are at least identical. 0068234 TOWOLDMON0021576 WATER_PCB-00006045 Converting To PYDRAUL Is Easy First, simply drain the petroleum oil and wipe the crankcase or lubricator. Thoroughly clean the exhaust valves and interstage equipment before filling the crankcase or lubricator with Pydraul. Pydraul will loosen carbonaceous deposits, varnishes and sludge. Unless these loosened deposits are cleaned from the system, they could clog pipelines and components, requiring additional downtime and production loss. Once the valves have been thoroughly cleaned of potentially dan gerous carbon deposits, Pydraul lubricants will keep them clean--and let compressors run longer between maintenance shutdowns. STANDARD CHECK FOR COMPRESSORS-Plastic separator bowls. Not all plastic separator bowls are suitable for Pydraul Rervice. Certain plastics are "crazed'' or softened when exposed to Pydraul. Bowls made of glass, brass, steel, and these plastics--polycarbon ate, polyethylene, or nylon--are recommended for use with Pydraul. If you have a question regarding the resistance of a particular plastic, Monsanto will be happy to advise you. Diaphragm valves. Pydraul lubricants have a sof tening effect on neoprene and buna N rubber diaphragms normally used for petroleum oil service. These diaphragms should be replaced with butyl rubber, EPK (ethylene propylene rubber), fluoroelaslomer, silicone or other compatible elastomer materials resistant to Pydraul fluids. Diaphragm sheeting is available from normal sources of supply. All diaphragms in unloading valves or downstream control valves should be replaced at the time of changeover. Diaphragms in valving downstream from separator systems or drying systems need not be replaced at changeover time, but should be changed on a preventative maintenance schedule as soon as practicable after operation on Pydraul is begun. For air compressors supplying air for instrumenta tion functions, mist eliminator systems are rec ommended to remove lubricant mists and moisture from air streams. A Monsanto development, a Brink mist eliminator is a particularly effective system, available from Monsanto in a series of lowcost mist eliminator systems to operate at all capacities. For information on a Brink series suitable for your compressor system, write to: Monsanto Engineering Sales Department 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 lubricants will soften and loosen some paints from crankcase interiors. These paint particles could block the lubri cant 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 removing 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 necessary: either replace the sight-glass fluid with one heavier than Pydraul or insert a metal bobber in the sightglass. 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 Manu facturing Company, has a higher density than Pydraul and is a completely satisfactory replace ment Metal bobbers. The alternate to using Fluoro chemical 101 is to modify the sight-glass lubricator by inserting a simple metal bobber. The bobber k installed by draining the sight-glass liquid, remov ing the guide wire and inserting the bobber. Opera tion 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 lubricators. Modification of the Madison-Kipp lubricator requires replacement of the entire sight-glass. Vacuum-sight lubricators. Vacuum-sight lubrica tors require no modification for Pydraul usage. 0068235 TOWOLDMON0021577 WATER_PCB-00006046 PYDRAUL Provides The Lubricating Qualities Of Premium Petroleum Oil Long years of service in air compressors of almost every type have proved the lubricating qualities of Pydraul air compressor lubricants equivalent to those of premium petroleum oil. Typical are the statements below from engineers reporting the performance of Pydraul as a lubricant. "Lubricating properties of Pydraul AC have been very satisfactory. Wear measurements on Molypak rings taken'approximately five months later indicate 0.003" wear. This is normal and con sidered very good. No corrosion of cylinder liners, valves and piping has been experienced, and service is very satisfactory." ' Compressor equipment: Cooper-Bessemer JM5 H "Pydraul AC--outside of reducing the fire hazard --also provides very satisfactory lubrication and protection of valves ... It seems rather logical to assume that the complete absence of deposits due to progressive oil oxidation and consequent high temperatures, shall help improve valve per formance and maintenance. The higher gravity of Pydraul seems to result in better mechanical separation, and its water-like permanent clean liness does not interfere with the cleanliness of surfaces contacted." Compressor equipment: Joy Manufacturing WN-112-E i 0066236 TOWOLDMON0021578 WATER_PCB-00006047 Lubricating Qualities TABLE 3 FILM STRENGTH JAW LOAD (LBS.) TORQUE (LBS. INCHES) Pydraul 625 Pydraul AC Pydraul AC Winter Grade 28 4100 3600 3700 89 98 92 TABLE 4 WEAR UNDER CONTINUOUS LOAD 1st 10 MINUTES 2nd 10 MINUTES Pydraul 625 Pydraul AC Pydraul AC Winter Grade 28 0.000618 0.000428 0.000450 0.000332 0.000285 0.000330 TABLE 5 TIMKEN (EXTREME PRESSURE)* Pydraul 625 Pydraul AC Pydraul AC Winter Grade 28 21,200.psi 23,250 psi 18,000 psi Film strength--Typical Petroleum Oil (measured by Timken Extreme Pressure)--5,000 to 8,000 psi. TABLE 6 SHELL FOUR-BALL WEAR (167F., 1 hour, 630 rpm., mm scar diameter) STEEL ON STEEL PYDRAUL 625 PYDRAUL AC PYDRAUL AC WINTER GRADE 28 10 kg 40 kg 0.26 0.62 0.32 0.70 0.30 0.65 TABLE 7 PUMP TEST' (Vickers V-105-E., 140F., 1000 hours.) PYDRAUL 625 PYDRAUL AC Ring, grams (loss or gain) -0.0013 Vane, grams (loss or gain) -0.0015 Bushing 2015 grams (loss or gain) --0.0045 Bushing 2016 grams (loss or gain) --0.0050 -0.0076 + 0.0014 + 0.0040 + 0.0045 *No data is presently available on Pydraul AC Winter Grade 28. DROP SIZE Drop size of a lubricant is important to determine an adequate lubricant injection rate to insure proper compressor lubrication. The rate ol 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 I Drops par I cubic centimeter Medium weight petroleum oil I Pydraul AC I 33 39 0068237 9 TOWOLDMON0021579 WATER_PCB-00006048 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 (right)have manufactured com pressors equipped for Pydraul, upon specification of the buyer, for over ten years. Many compressors have operated on Pydraul lubricants continually with exhaust air temperatures of 350F. Pydraul is also used to lubricate cylinders in compressors operating at pressures over 4500 psig. Mixing Compatibility TABLE 8 PYDRAUL WITH OTHER HYDRAULIC FLUIDS FYRQUEL&Ebe, 90 150 220 300 550 HOUGHTO-SAFE 1010 1055 1120 1130 625 YES YES YES YES YES AC AC-WG28 YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES 10 OObBZ38 TOWOLDMON0021580 WATER_PCB-00006049 American Messer Corporation I 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 i When installing new equipment, it is best to start with an increased lubricant feed rate and reduce this rale by successive increments. Inspection of cylinder walls and valves will indicate the proper degree of wetting. 1111 m ! 0066^^9 11 TOWOLDMON0021581 WATER_PCB-00006050 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, certain pre cautions are advisable. Skin contact. Repeated or continuous skin con tact with Pydraul fluids should be avoided. Pydraul fluids act as a solvent and repeated or prolonged skin contact can cause dry skin and chapping. Eye contact. Although eye irritation studies using Pydraul fluids at full strength indicate Pydraul to be an irritant., there is no evidence to show Pydraul causes permanent eye tissue damage. If Pydraul fluids are splashed or sprayed into the eyes, mod erately severe pain and irritation may result. Eyes should be thoroughly flushed with water and the workman referred to a physician. To relieve irritation, physicians 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 con centrations of vapors, inhalation <5f vapors at high temperatures should be prevented. Air samples were taken from the line of a Joy Manufacturing air compressor which had operated on Pydraul AC for three years. Filter paper and silica gel samples were collected and analyzed using a Beckman Spectrophotometer after iso-octane or iso-propanol extraction. No concentrations of the major components of Pydraul AC could be detected. No serious hazard is anticipated from vapors of Pydraul fluids; however, 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 simply good industrial practice for any compressor fluid or lubricant. 0068240 TOWOLDMON0021582 WATER PCB-00006051 DISTRICT SALES OFFICES ALL DIVISIONS A1LANTA, GEORGIA 30326 lenox Towers East 3400 Peachtree Rd. N. E.--Suite 1711 Tot. (404)577-2260 BOSTON, MASSACHUSETTS 02149 Everett Station To/. (6J7J 387-5010 CHICAGO, ILLINOIS 3158 Des Plaines Ave. Dos Plaines, Illinois 60018 Tel. (312) 296 6688 CINCINNATI, OHIO 45206 J501 Madison Road Tel. (513) 751-6707 CLEVELAND, OHIO44122 3645 Warrensville Center Rd. Tel. (216) 991-5400 DETROIT, MICHIGAN 48235 500 Northland Towers East Tel. (313) 357-0910 HONOLULU, HAWAII 96812 205 Pacific International Bldg. 677 Ala Moana Blvd., P. O. Box 3824 Tel. (808) 512-744 HOUSTON, TEXAS 77002 J300 Main Street lei. (713) 223-4011 LOS ANGELES, CALIFORNIA 90022 6670 E. Flotilla St. Tel. (213) 723-2492 MINNEAPOLIS, MINNESOTA 55402 912 Northstar Center 110 S. Seventh St. Tel. (612) 339-4651 NEW YORK, NEW YORK 10017 277 Park Avenue Tel. (212) 922-4111 PITTSBURGH, PENNSYLVANIA 15222 No. 4 Gateway Center Bldg. Room 534 Tel. (412) 261-2156 ST. LOUIS, MISSOURI 63166 BOO N. Lindbergh Blvd. Tel. (314) 694*J000 SAN FRANCISCO BAY AREA 2710 Lafayette, Santa Clara, Calif. 95052 Tel. (408) 243-0414 SEATTLE, WASHINGTON 98104 911 Western Avenue Tel. (206) 622-4203 SPRINGFIELD, MASSACHUSETTS 01101 730 Worcester Ave. Tel. (413) 788-6911 WILMINGTON, DELAWARE 19803 2005 Concord Pike, Fairfax Tel. (302) 658-6531 "Nothing contained herein is to be construed as a recommendation to use ary product in conflict with any patent. MONSANTO MAKES NO WARRANTIES AS TO THE FITNESS OR MERCHANTABILITY OF ANY PRODUCTS REFERRED TO. no guarantee of satisfactory results from reliance upon contained information or recommendations, and disclaims all liability for any resulting loss or damage." PYDRAUL Monsanto 006fl4i TOWOLDMON0021583 WATER_PCB-00006052 Monsanto FUNCTIONAL FLUIDS Monsanto Company, 800 North Lindbergh Blvd., St. Louis, Missouri 63166 09ce-iGt-Lieft TOWOLDMON0021584 WATER_PCB-00006053