Afton Chemical's Microbotz Hydraulic Guide Sample Content

A COMPREHENSIVE GUIDE TO HYDRAULIC

HYDRAULIC

CONTENTS

INTRODUCTION

1

MARKET 4 HYDRAULIC ANALYSIS

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HYDRAULIC APPLICATIONS

• Introduction to hydraulic systems • Hydraulic manufacturers – at-a-glance • How hydraulics work – the basics • How hydraulics work – the details • Types of hydraulic pumps • Actuators/motors • Lubricant system design and components

9 11 12 14 15 20 21

2 HYDRAULIC LUBRICATION NEEDS • The role of hydraulic fluids in 25 industrial applications • Reliability and durability 26 • What role do additives play?

30 • Wear prevention 30 • Metal surface protection 31 • Sealing material compatibility 31 • Deposit control 31 • Effectiveness despite 32 varying conditions • Industrial hydraulic fluids in-service 33 • In-service condition monitoring 33 • Solving persistent lubricant problems 35 • Introduction to hydraulic fluid 36 classifications • Environmentally acceptable lubricants 38

OF KEY GLOBAL 3 OVERVIEW HYDRAULIC OEMs • Introduction • Key hydraulic OEMs • Hydraulic component manufacturers • Mobile equipment builders • Stationary equipment builders (plastic injection molding machinery)

43 43 44 49 56

• Global industrial hydraulic equipment market • Global hydraulic equipment market 2015 – 2020 ($ billions) • Global hydraulic equipment market by region, 2015 – 2020 • Global hydraulic equipment market by product, 2015 – 2020 • Pump and motor • Estimated global pump and motor market share by type • Mobile and stationary (industrial) • Global hydraulic equipment market share by segment • Global hydraulic fluid market by region and end-use • Estimated demand for industrial hydraulic fluids by region, 2015 • Estimated demand for industrial hydraulic fluids by industrial end-use segment, 2015 • Impact of key trends on hydraulic fluid market • Hydraulic market segmentation • Lubricant market segmentation fluid market

62 62 63 64 64 64 65 65 65 66

67 68 68

KEY HYDRAULIC PERFORMANCE 5 TESTS EXPLAINED • Description of key tests 71 • Specification cross reference tables 88

THE AFTON INDUSTRIAL 6 HYDRAULIC PORTFOLIO • • • • • • •

Hydraulic range Hydraulic market segmentation Hydraulic product benefits Components Afton PMA viscosity index improvers Afton pour point depressants Hydraulic portfolio – at-a-glance

93 94 95 99 100 101 102

7 APPENDICES • Industrial hydraulic dictionary • Industrial hydraulic acronyms • Industrial hydraulic base stocks explained • Industrial hydraulic base stock comparisons

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61

105 108 109 111

INTRODUCTION Afton Chemical is a leading global supplier of industrial lubricant additive packages.

The Afton Industrial portfolio covers a broad range of industrial lubricant additives, including additive packages developed for Wind Turbine, Industrial Gear, Turbine, Hydraulic, Grease and Slideway applications.

WIND TURBINE

INDUSTRIAL GEAR

TURBINE

HYDRAULIC

GREASE

SLIDEWAY

COLOR CODING FOR APPLICATION GROUPS

This guide focuses on hydraulic applications. It covers the different types of hydraulics and how they work, market trends in hardware and lubrication as well as the additives and specifications for industrial hydraulics, and some examples of the many diverse end use applications. It also presents the Afton Industrial Portfolio.

It aims to be a useful reference guide for our customers, our distributors, the OEMs and our internal staff. This guide is the fifth in a series of guides from Afton Industrial and forms part of a limited edition collectible box set of guides to industrial lubricants.

We hope you will find them interesting and informative!

The Afton Industrial Team, June 2017

6

1

HYDRAULIC APPLICATIONS

Types of Hydraulic Pumps The pump is the heart of most hydraulic systems. The pump converts the mechanical power supplied to it via a rotating shaft into fluid flow and thus, in a closed circuit, fluid pressure. The pump must be driven by a power source; this could be an electric motor for stationary equipment and a diesel or gasoline engine for mobile equipment.

There are two main categories of hydraulic pump: •

Fixed displacement, such as gear pumps and some types of vane pump

•

Variable displacement, such as piston pumps and dynamic displacement type vane pumps.

FIXED DISPLACEMENT PUMPS EXTERNAL GEAR PUMP External gear pumps consist of two spur gears meshing within a chamber. The first gear is connected to the input shaft and drives the second gear (the idler). Fluid is drawn into the inlet chamber by the sub ambient pressure that exists when the gear teeth separate. Space that was taken up by the metal gear teeth is now empty space at a lower pressure than the surrounding fluid, so fluid flows towards this area.

When the gear teeth mesh on the outlet side, the fluid is forced out of the gap. This continuous separation and meshing results in a smooth flow of fluid from the inlet of the pump to its outlet.

EXTERNAL GEAR PUMP

15

HYDRAULIC LUBRICATION NEEDS 2

Hydraulic Lubrication Needs THE ROLE OF HYDRAULIC FLUIDS IN INDUSTRIAL APPLICATIONS Many different industries and applications use hydraulic systems, and they are often the major driver in final product manufacture.

SUB-SEA HYDRAULICS

ASSEMBLY PLANT

PULP AND PAPER

OFF-ROAD

CEMENT MANUFACTURE

GLASS

INDUSTRIAL HYDRAULIC APPLICATIONS DOCKYARDS

OFF-SHORE OIL AND GAS

FOOD PROCESSING

METAL MANUFACTURE

MARINE

POWER GENERATION

RUBBER AND PLASTICS

Application and environment are the key factors in the design of every hydraulic system. Whether that system is for indoor stationary equipment or mobile outdoor machinery used in desert heat or arctic cold, an appropriate combination of prime movers, pumps, valves and actuators can be found.

25

KEY HYDRAULIC PERFORMANCE TESTS EXPLAINED

5

Description

of key tests 1. S TANDARD FOAM TEST (ASTM D892) PURPOSE Measures the tendency of lubricants to foam and the stability of any foam produced.

Foaming can be a serious problem in hydraulic systems, causing improper lubrication, cavitation and overflow loss, leading to system failure.

METHOD The oil sample is placed in a graduated cylinder and air is blown into the sample for 5 minutes. The volume of foam is then measured. The test is done under three different sets of conditions: •

Sequence I: Fresh oil at 24°C

•

Sequence II: Fresh oil at 93.5 ± 0.5°C

•

Sequence III: Oil from Sequence II once it has cooled to 24°C

Foaming tendency is the volume of foam (ml) present immediately after the test.

ASTM D892 TESTING EQUIPMENT

Foam stability is the volume of foam (ml) still present 10 minutes after the test.

RESULTS A foaming tendency of 50 ml and foam stability of 10ml would be reported as 50/10.

For hydraulic fluids the first figure (foam tendency) is typically 50 or below, while the second figure (foam stability) must be 0.

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THE AFTON INDUSTRIAL HYDRAULIC PORTFOLIO

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The Afton

Industrial Hydraulic

portfolio

HYDRAULIC RANGE Afton Industrial offers a complete portfolio of Hydraulic additive packages, all with proven performance in the field. From premium tier anti-wear hydraulic additives through to entry tier R&O and anti-wear products, our advanced additive technology extends the life of hydraulic systems and helps minimize lifecycle costs. Our product range is ultimately designed to deliver improved productivity, reliability and operating efficiency for the end-user.

FUTURE-PROOFING HYDRAULIC FLUIDS Afton maintains strong relationships with hydraulic OEMs, which includes pump, motor, seal and filter producers as well as manufacturers of the mobile and stationary machines that use these components.

These OEM relationships enable us to stay ahead of the curve; our solutions are designed to meet current and future industry challenges, such as improving reliability, increasing power density, reducing environmental impact, and increasing energy efficiency, as well as meeting and exceeding the latest performance specifications.

In our research labs we operate a range of critical hydraulic test rigs from global pump and motor OEMs: these are essential to achieving the most demanding OEM approvals and demonstrating the robust performance of our additives in customers’ hydraulic fluids.

EXCAVATOR

93

APPENDICES

103

Hydraulic

dictionary Actuator (Hydraulic)

A device for converting hydraulic fluid pressure into motion.

Additive Any material added to a base oil to change its properties, characteristics or performance.

Additive Package/Concentrate

Liquid composition containing a mixture of additives, added to a base oil to improve its performance.

Adiabatic Compression In oil subjected to very high pressures (for example in a bearing) entrained air bubbles are compressed, resulting in very high localised temperatures that can degrade the oil.

Air Release (Time) Measure of how quickly entrained gases are released from oil; smaller values indicate faster separation.

Antioxidant Molecule that inhibits the oxidation of other molecules, usually through removing or isolating free radical intermediates or peroxides.

Anti-wear Additive that prevents wear by forming a protective surface layer (usually phosphorus), preventing metal-to-metal contact and abrasion.

Axial (Piston) Pump A piston pump that uses a swash plate to convert constant rotational speed into variable fluid discharge.

Base Stock Base fluid, usually a refined petroleum fraction or selected

synthetic material, into which additives are blended to produce a finished lubricant.

Bleed and Feed Partial oil replenishment: a portion of older lubricant volume is drained from the reservoir and replaced with recommended fresh lubricant, in an effort to extend overall fluid life without draining and refilling the entire reservoir.

Clevis

joint at the exterior end of the hydraulic rod that creates a The movable connecting joint.

Corrosion Inhibitor Additive that protects lubricated metal surfaces from chemical attacks by water or contaminants.

Demulsibility

A lubricant’s ability to separate from water.

Deposit Term referring to a precipitate, insoluble, film or sediment that has settled out of a lubricating oil onto machinery surfaces; includes varnish and sludge.

Displacement Fluid

See Flush Fluid.

Ecolabel Identifies those products proven to be environmentally preferable overall within a specific product category.

Electrohydraulic Servo Valve Electrically operated valve controlling how hydraulic fluid is ported to an actuator.

Electrostatic Arcing

See Electrostatic Spark Discharge

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HYDRAULIC

HYDRAULIC

ASIA PACIFIC Afton Chemical Asia Pte. Ltd. 111 Somerset Road #09-05 TripleOne Somerset Singapore 238164 T: +65 6732-0822

EUROPE, MIDDLE EAST, AFRICA AND INDIA Afton Chemical Limited London Road, Bracknell Berkshire RG12 2UW England T: +44 1344 304-141

LATIN AMERICA Afton Chemical Industria de Aditivos LTDA Avenida Rio de Janeiro 901 (Parte) CEP-20931-675 Brazil T: +55 21 3295-4050

NORTH AMERICA Afton Chemical Corporation 500 Spring Street Richmond VA 23219 USA T: +1 804-788-5800

www.aftonmicrobotz.com ©2017. Afton Chemical Corporation is a wholly owned subsidiary of NewMarket Corporation (NYSE:NEU).

AFTON®, HiTEC®, and Microbotz™ are trademarks owned by Afton Chemical Corporation.

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06/17