NATIONAL THERMAL POWER CORPORATION OPERATION DIVISION FORMAL DOCUMENTATION SYSTEM OPERATION GUIDANCE NOTE- OGN/OPS/MECH/014

Issue No. : 1 Date : September 1994

FIRE RESISTANT FLUIDS FOR CONTROL SYSTEMS -AVOIDANCE OF MIXING NATURAL AND SYNTHETIC BASED FLUIDS WITHIN THE SAME CONTROL SYSTEM

Approved for Implementation by ..................................................... Director (Operation) Date :.............................................

Enquiries to : Executive Director, Operation Services.

FIRE RESISTANT FLUIDS FOR CONTROL SYSTEMS AVOIDANCE OF MIXING NATURAL AND SYNTHETIC BASED FLUIDS WITHIN THE SAME CONTROL SYSTEM

CONTENTS Page Nos. 1.0 2.0 3.0 4.0 5.0 6.0 Introduction Superseded Documents Scope Operation Requirements Recommendations Review 1 2 2 2 2 3

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FIRE RESISTANT FLUIDS FOR CONTROL SYSTEMS AVOIDANCE OF MIXING NATURAL AND SYNTHETIC BASED FLUIDS WITHIN THE SAME CONTROL SYSTEM
1.0 INTRODUCTION NTPC is importing control fluid for its 500 MW Turbine Governing systems from M/s STAUFFERS CHEMICAL CO. WESTPORT, France. The manufacturer claims the fluid as single component and is a pure non additive phosphate ester in the brand name of FYRQUEL-EHC. It is differentiated from other members of the series in having viscosity Saybolt Universal Second (SUS) as 220 at 1000F. The manufacturer further claims it to be free from any hydrocarbon lubricating oil blending. The manufacturer is silent about declaring its origin from Natural or Synthetic background. However, in other countries Fire resistant fluid is supplied in different forms. Fire resistant hydraulic fluid is supplied based on both naturally and synthetically derived phosphate esters. There are differences between the properties of the natural and synthetic bases and in the additives, such as rust inhibitors, which are used in each type of fluid. Laboratory tests carried out by one of the suppliers suggests that the two types of fluid can be satisfactorily mixed, however this has not been confirmed by full scale field trials. Information from Ciba-Geigy, who manufacturer all the FRFs used by National Power but market them via oil company branded products, suggests that, as a result of the reducing availability of the base material, the natural based fluid is becoming difficult to supply. FRFs which are supplied by different oil companies but are derived from the same base may have different additives which may be incompatible.

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2.0 3.0

SUPERSEDED DOCUMENTS - Nil SCOPE All stations using FRFs in the Control Systems.

4.0 4.1

OPERATION REQUIREMENTS Because of concern over the effects of mixing the two types of fluid in the same system, users of FRFs are advised not to mix natural and synthetic before the results of any fields trials are known. This is in spite of any apparent compatibility which may be suggested in the product data. If oil companies cannot supply the currently used natural FRF in sufficient quantities for topping up purposes, it will be necessary to change the full charge of fluid until such time as the results of any mixing trails are known. Fluids from different suppliers, which may be derived from the same source but have different additives, should not be mixed without prior consultation with Engineering Division and continuity of condition monitoring by the original supplier. RECOMMENDATIONS (1) Natural and synthetic based FRFs must not be mixed within the same system. If supplies of the previously used FRF, from either base, cannot be obtained for topping up purposes, then the full system charge must be changed to the fluid of the revised base. FRFs used for lubrication purposes may have hydro carbon oils and additives pf different quality. So, they should not be mixed.

4.2

4.3

5.0

(2)

(3)

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6.0

REVIEW The Executive Director, Operation Services, will be responsible for reviewing this document on 2 - yearly basis or as necessary.