FM Global

Property Loss Prevention Data Sheets

7-98
May 2003
Page 1 of 7

HYDRAULIC FLUIDS

Table of Contents
Page
1.0 SCOPE ................................................................................................................................................... 2
1.1 Changes .......................................................................................................................................... 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 Introduction ...................................................................................................................................... 2
2.2 Occupancy ....................................................................................................................................... 2
2.2.1 General .................................................................................................................................. 2
2.2.2 Less Flammable Hydraulic Fluids ......................................................................................... 2
2.3 Protection ......................................................................................................................................... 3
2.3.1 Petroleum-Base Hydraulic Oils ............................................................................................. 3
2.4 Equipment and Processes .............................................................................................................. 4
2.4.1 Petroleum-Base Hydraulic Oils ............................................................................................. 4
2.5 Operation and Maintenance ............................................................................................................ 5
2.5.1 Petroleum-Base Hydraulic Oils ............................................................................................. 5
2.6 Training ............................................................................................................................................ 5
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 5
3.1 General ............................................................................................................................................ 5
3.1.1. Causes of Oil Release ......................................................................................................... 5
3.1.2. Fire Characteristics ............................................................................................................... 5
3.1.3. Less Flammable Hydraulic Fluids ........................................................................................ 5
4.0 REFERENCES ....................................................................................................................................... 6
4.1 FM Global ........................................................................................................................................ 6
4.2 Others .............................................................................................................................................. 6
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 6
APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 6
APPENDIX C SUPPLEMENTARY INFORMATION ..................................................................................... 6
C.1 General ........................................................................................................................................... 6
C.2 Less Flammable Hydraulic Fluids ................................................................................................... 6

List of Tables
Table 1. Sprinkler System Water Demands for Hydraulic Equipment Using Petroleum-Base Hydraulic
Oils ................................................................................................................................................... 4
Table 2. Petroleum-Base Hydraulic Fluid Systems Greater than 100 Gallon (380 l) Aggregate
Capacity or Individual Systems ....................................................................................................... 4

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7-98

Hydraulic Fluids

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FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet describes the various types of hydraulic fluids and provides recommended loss prevention
practices relating to their use. Primary emphasis is placed on the fire hazard of petroleum-base hydraulic oils.
1.1 Changes
May 2003. Minor editorial changes were made for this revision.
2.0 LOSS PREVENTION RECOMMENDATIONS
2.1 Introduction
2.1.1 Use a less flammable hydraulic fluid where possible. Field experience with the Approved (see Appendix A for definition) fluids has indicated that they can be used in many hydraulic systems and should greatly
reduce the hazards of fire. Where a less flammable hydraulic fluid is not used, recommendations relating
to petroleum-base hydraulic oils should be followed. Very large, e.g., 1000 gallons (3800 l) or greater capacity petroleum-base hydraulic oil systems should be located in sprinklered, cutoff rooms.
2.2 Occupancy
2.2.1 General
2.2.1.1 Emergency shutoff switches should be provided for shutting down hydraulic pumps in the event of
a pipe failure or fire. They should be well marked and readily accessible under any anticipated fire conditions.
2.2.1.2 In hydraulic systems with pressures exceeding 200 psi (1.4 MPa), SAE (Society of Automotive
Engineers) 1010 dead-soft, cold-drawn seamless-steel tubing (or equivalent) should be used. A safety factor
of eight over maximum working pressure should be used. Tubing is preferable to pipe, because it can be
bent to fit in restricted spaces with a minimum number of fittings, reducing the number of possible leakage
points.
Solderless, steel fittings of the flareless locking-sleeve-type or flare-type should be used.
2.2.1.3 Avoid use of threaded pipe. In large piping or in connections to hydraulic cylinders or manifolds, welded
joints done by qualified welders in accordance with accepted American Welding Society (AWS) or ANSI/
ASME procedures are preferred. Where threaded connections are used, the requirements of ANSI/ASME
B1.20.1 Pipe Threads, General Purpose, should be met. A safety factor of eight over maximum working
pressures should be used.
2.2.1.4 Tubing runs should have as few bends as possible, but should have at least one bend to provide
for thermal expansion and contraction. The minimum radius of tube bend should be three tube diameters.
2.2.1.5 Where hose must be used for flexible connections, it should be steel reinforced, designed for the
hydraulic fluid being used, and capable of withstanding four times the maximum working pressure. Hose
couplings and fittings and minimum bending radii should be in accordance with the hose manufacturers
instructions. Hose should not rub against other objects as a result of machine movement, vibration, or
pressure surges.
2.2.1.6 Piping and tubing should be anchored or secured to minimize failure due to vibration. Pipe supports
should not prevent normal thermal expansion. Bolted supports tend to loosen as a result of vibration, and
should be tightened regularly using torque wrenches. Often, vibration due to pressure surges can be minimized by incorporating an accumulator in the system.
2.2.1.7 Leaking tubing or containers should be repaired, and any leaking fluid should be cleaned up promptly.
2.2.2 Less Flammable Hydraulic Fluids
2.2.2.1 New Installations
a) Before purchase of new hydraulic equipment, manufacturers should be consulted so that equipment
suitable for use with less flammable hydraulic fluids can be obtained.
b) Pumps, seals, gaskets, packings and other system components should be suitable for the less
flammable fluid to be used.

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Hydraulic Fluids
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2.2.2.2 Conversions of machines to use less flammable fluids.

a) Procedures recommended by the manufacturer of the less flammable fluid should be followed in
converting machines.
b) Before the changeover to a new fluid, a record should be made of normal operating conditions, including temperatures, pump inlet and outlet pressures, and flow rates, to determine if equipment is operating properly before and after conversion.
c) In preparing for a change to a new fluid, the old fluid should be completely drained from the system.
Do not mix fluids of different types, or of the same type from different suppliers.
d) Replacement of seals, gaskets, packing and filters should be done when recommended by the fluid
supplier.
e) Paints that are not compatible with the new fluid should be removed from the reservoir and other internal
parts of the system.
f) The system should be filled with the new fluid and operated for several hours and then drained to
completely remove the fluid and particulate matter. The system should then be refilled with the new fluid.
g) The newly converted system should be closely checked in operation to see that the pump, filters, heat
exchanger and seals are functioning properly, that pump suction vacuum is not excessive, and that proper
fluid viscosity and stability is being maintained.
2.2.2.3 Fluid maintenance
a) Water-glycol, water-oil emulsions and high water base fluids should be checked for viscosity, water
content and acidity at three- to six-month intervalsmore frequently if operated at high temperatures.
Distilled or treated water should be added when necessary, as well as other additives, in accordance with
manufacturers instructions.
b) Synthetic fluids or blends should be checked for viscosity, acidity, particulate matter and oil or water
content at least annually. When necessary, the fluid should be filtered or reclaimed in accordance with
manufacturers instructions.
2.2.2.4 Where less flammable hydraulic fluids are used, the following protection recommendations for areas
using petroleum-base hydraulic oils would not be needed unless required for other combustibles or flammable
liquids present.
Note: Further guidance on the use of less flammable hydraulic fluids can be found in ISO 77451989(E),
Hydraulic Fluid PowerFire Resistant FluidsGuidelines For Use.
2.3 Protection
2.3.1 Petroleum-Base Hydraulic Oils
The degree of protection needed in the following recommendations may depend on 1) the total quantity of
petroleum-base hydraulic oil that can be released from the hydraulic equipment, assuming pumps are not shut
off; and 2) the normal presence of ignition sources during equipment operation. These include molten metal,
heaters, or other hot surfaces above the autoignition temperature of the oil, open flames, or sparkproducing equipment, such as welding machines.
2.3.1.1 Provide automatic sprinklers over and at least 20 ft (6 m) beyond the hydraulic equipment. Complete
sprinkler protection is needed if combustible construction or occupancy extends beyond. Sprinklers also
should be provided for shielded areas, such as pits beneath equipment or areas under platforms. For water
demands, see Table 1. Wet systems using high temperature rated sprinklers are preferred.
Exception: Sprinklers may be omitted over a single small hydraulic system or multiple adjacent small systems, i.e., within 20 ft (6 m) of each other. This is acceptable only if the following criteria are met: the aggregate oil capacity does not exceed 100 gal (380 l); the construction and adjacent occupancy is noncombustible;
ignition sources normally are not present; business interruption potential is low (i.e., low-valued product
worked/manufactured on equipment which can be readily replaced, or production can be readily made up
by other existing equipment); and provisions exist for automatic or prompt manual shutdown of the system.

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Hydraulic Fluids

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FM Global Property Loss Prevention Data Sheets

Table 1. Sprinkler System Water Demands for Hydraulic Equipment Using Petroleum-Base Hydraulic Oils

No individual units have

more than 100 gal (380 l)
capacity.

Individual units that have

more than 100 gal (380 l)
capacity. Examples of
occupancies where these
might be found: die casting,
metal extruding, plastic
molding, hydraulic presses.

Water Demand
Use the table applicable to
the surrounding occupancy
from Data Sheet 3-26,
Fire Protection Water
Demand for Nonstorage
Sprinklered Properties, or in
the appropriate occupancy
data sheet.
Water supply must meet
both applicable surrounding
occupancy table from Data
Sheet 3-26 or in the
appropriate occupancy data
sheet and Table 2 of this
data sheet.

Exception to the General

Category
Multiple adjacent units each
100 gal (380 l) or less
separated by no more than
20 ft (6 m) but with greater
than 100 gal (380 l)
aggregate capacity.

Water Demand for the

Exception
Water supply must meet
both applicable surrounding
occupancy table from Data
Sheet 3-26 or in the
appropriate occupancy data
sheet and Table 2 of this
data sheet.

Table 2. Petroleum-Base Hydraulic Fluid Systems Greater than 100 Gallon (380 l)
Aggregate Capacity or Individual Systems
Type of
Sprinkler
System
Wet
Wet
Dry
Dry

Area
Sprinkler
Density,
Temperature Rating,
gpm/ft2
(mm/min)
F (C)
High
0.20
286 (141)
(8)
Ord.
0.20
160 (71.1)
(8)
High
0.20
286 (141)
(8)
Ord.
0.20
160 (71.1)
(8)
Hose stream demand: 500 gpm (1900 l/min). Duration of demand: 60 min

of Demand,
ft2
(m2)
3000
(280)
4000
(370)
5000
(460)
6000
(560)

2.3.1.2 Fire extinguishers suitable for flammable liquid fires, preferably dry chemical or air foam (AFFF type),
should be provided. If the hydraulic system is large, i.e., containing more than 100 gal (380 l), a small hose
with spray nozzle should be provided.
2.4 Equipment and Processes
2.4.1 Petroleum-Base Hydraulic Oils
2.4.1.1 Provide an automatically actuated means for shutting down the oil pump and shutting off flow from
accumulators for hydraulic systems with individual reservoirs containing more than 100 gal (380 l) of
petroleum-base hydraulic oil. Automatic shutdown of hydraulic systems may be accomplished through the
use of a sprinkler waterflow switch; a thermally actuated fire detector/device rated at least 50F (30C) above
the highest anticipated operating environment temperature, located directly above the hydraulically operated equipment; or an oil reservoir liquid level switch electrically interlocked with the power supply to the oil
pump. The oil reservoir liquid level switch arrangement should be used only where the hydraulic oil system release can be limited to 25 gallons (95 l) or less.
Exception: For an adequately sprinklered area per Recommendation No. 2.3.1.1 above, an automatic shutoff(s) need not be provided if a) loss or major damage to the machine of fire origin does not present a significant business interruption potential (i.e., business interruption potential is low as defined above in
Exception to Recommendation No. 2.3.1.1); or b) if a significant business interruption potential exists (e.g.,
high-valued or critical machine), the area is constantly attended by well-trained operators per Recommendation No. 2.6.1 below with at least one remote manual shutoff that will be readily accessible under any anticipated fire condition.

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7-98
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Note: Concern has been expressed that rapid shutdown of equipment in the midst of an operating cycle
could cause further damage and/or business interruption. A programmed/delayed shutdown of equipment
should be considered, provided additional oil release can be minimized where such circumstances can be
shown to exist.
2.5 Operation and Maintenance
2.5.1 Petroleum-Base Hydraulic Oils
2.5.1.1 In addition to other recommended precautions for maintenance hot work operations, in areas where
petroleum-base hydraulic oils are used, all oil deposits should be cleaned up, and the hydraulic system
depressurized, before any hot work operation is conducted.
2.6 Training
2.6.1 In addition to other recommended emergency organization responsibilities, equipment operators should:
a) Be trained in the location, function and proper operation of emergency oil shutoff switches.
b) Be trained in the location, function and operation of fire extinguishers and fire hose equipment.
c) Be trained in precautions to avoid accidental rupture of hydraulic piping, tubing and hose.
d) Be trained in procedures for prompt cleanup of spills or leaks.
3.0 SUPPORT FOR RECOMMENDATIONS
3.1 General
Pressurized oil in hydraulic systems presents a considerable fire hazard, particularly in processes where ignition sources are constantly present, as in plastics forming, die casting, automatic welding and melting, and
heat-treating of metals. Escaping hydraulic oil has caused many severe fires, particularly where building contents or construction were combustible and sprinkler protection was lacking.
3.1.1. Causes of Oil Release
High pressure pipe with welded and screwed joints, steel and copper tubing, and metal-reinforced rubber
hose are used to conduct oil to the various units, at pressures ranging up to 10,000 psi (69 MPa). Failure of
piping, particularly at the threaded sections, failure of valves and gaskets or fittings, pulling out of copper
and steel tubing from fittings, and rupture of flexible hose have been the principal causes of oil release from
the system. Lack of adequate supports or anchorage to prevent vibration or movement of piping has been
a factor in these failures. Repeated flexing and abrasion of rubber hose against other hose or parts of
machines have created weak spots, which eventually resulted in rupture. Tubing under pressure has
released oil when accidentally cut by welding torches or stepped on during maintenance procedures.
3.1.2. Fire Characteristics
When hydraulic oil is released under pressure, the usual result is an atomized spray or mist of oil droplets
that may extend up to 40 ft (12 m) from the break. The flammable oil spray is ignited readily by hot surfaces, such as heated or molten metal, electric heaters, open flames or welding arcs. The resulting fire usually is torch-like with a very high rate of heat release.
Automatic sprinkler discharge can protect the building structure and prevent involvement of other combustibles, but the torch-like fire presents little burning surface for cooling or wetting. A high heat release can
continue, opening many sprinklers, until the oil discharge is stopped.
3.1.3. Less Flammable Hydraulic Fluids
Less flammable hydraulic fluids have been developed to replace petroleum-base oils in all types of hydraulic systems. These fluids exhibit some degree of combustibility. If sprayed onto very hot surfaces, a flaring
fire can occur. Loss experience indicates that properly maintained systems with less flammable hydraulic
fluids significantly reduce the extent of damage in a fire as compared to sytems with petroleum-base oils.

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FM Global Property Loss Prevention Data Sheets

4.0 REFERENCES
4.1 FM Global
Data Sheet 3-26, Fire Protection Water Demand for Nonstorage Sprinklered Properties.
Data Sheet 13-8, Power Presses.
4.2 Others
ANSI/ASME B1.20.1, Pipe Threads, General Purpose.
ISO 7745-1989(E), Hydraulic Fluid PowerFire Resistant FluidsGuidelines for Use.
APPENDIX A GLOSSARY OF TERMS
Approved: references to Approved in this data sheet means the product and services have satisfied the
criteria for FM Approval. Refer to the Approval Guide for a complete listing of products and services that are
FM Approved.
APPENDIX B DOCUMENT REVISION HISTORY
May 2000. This revision of the document has been reorganized to provide a consistent format.
APPENDIX C SUPPLEMENTARY INFORMATION
C.1 General
Hydraulic fluids are used for transmitting power or motion to the various parts of equipment and machines.
The function of the fluid may be power multiplication as in the hydraulic presses, actuation of automatic
equipment as in die casting, or remote actuation or precision control of various machines and instruments.
Hydraulic fluids are used in die casting and plastic molding machines; mining equipment; automatic welding equipment; machine tools, such as drill presses, milling machines, grinders, boring mills, shapers, saws,
broaching machines, punch presses, shears and riveters; and in hydraulic couplings, torque converters, oil
cookers, elevators, lift trucks, heat-treating furnace-door operations and melting-furnace tilting units. Large
hydraulic presses are an important application of hydraulic power transmission. (See Data Sheet 13-8, Power
Presses, for further information.) Most hydraulically operated equipment has individual oil systems located
nearby, although some equipment, particularly hydraulic presses, may have very large or centralized hydraulic oil systems located in a cut-off area.
Earlier hydraulically operated equipment used water as the hydraulic medium, but because of its corrosive
effect on the metallic parts of the machines and its lack of lubricity, it was replaced by petroleum-based oil.
Except for its fire hazard, oil is an ideal hydraulic fluid. It is not corrosive, does not affect seals, has good lubricating properties, can be obtained in various viscosity ranges, and is readily available. Flash points range from
300 to 600F (150 to 315C); autoignition temperatures range from 500 to 750F (260 to 400C).
C.2 Less Flammable Hydraulic Fluids
Approval tests for less flammable fluids simulate the discharge from a fractured high pressure pipe or fitting by discharging fluid at 1000 psi (6.9 MPa) pressure through an atomizing nozzle. The fluid at 140F (60C)
is sprayed on an inclined steel surface heated to 1300F (704C), and into a torch flame. When an Approved
fluid is ignited by the steel surface, the flame will not follow the fluid spray when swung away from the hot
surface. If the Approved fluid is ignited by the torch, the flame will go out within five seconds after the torch
is removed.
Approved less flammable fluids are either of the high water base (oil-in-water emulsion), water-in-oil emulsion, water-glycol, or synthetic types. These are referred to internationally as HF-A, HF-B, HF-C and HF-D fluids respectively.
High Water Base Fluids (Oil-in-Water Emulsions)
High water base fluids (HF-A) contain 90% or more water. Additives to the water are generally synthetics
or soluble oils. These fluids have viscosities approaching that of water and are used mainly in light-duty
applications pressures below 1000 psi (6.9 MPa)using special pumps.

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Recommended temperature limits are 40 to 120F (4 to 49C). High water base fluids are compatible with
most types of seals and gaskets, except those made from cork, paper, leather and synthetic fibers.
Water-in-Oil Emulsions
Water-in-oil emulsions (HF-B) consist of 35% to 40% water in mineral oil, with a small amount of emulsifying
agents, rust inhibitors and anti-wear additives. The water is dispersed in fine droplets in the continuous oil
phase.
Recommended temperature limits are 15 to 150F (10 to 65C). At temperatures above 150F (65C), a
periodic addition of water normally is required. Either excessive heating or cooling can upset emulsion
stability. Loss of water from emulsions tends to reduce viscosity and increase flammability.
Water-in-oil emulsions are compatible with most types of seals and gaskets, except those made from cork,
paper, leather and synthetic fibers.
Water-Glycol Fluids
Water-glycol fluids (HF-C) normally consist of 35% to 50% water for fire resistance, ethylene or propylene
glycol to improve low temperature properties, and additives for proper viscosity and resistance to corrosion,
wear and bacteria.
Recommended temperature limits are 0 to 150F (18 to 65C) with normal operation at 120 to 150F
(49 to 65C). At temperatures above this range, the rate of water evaporation is such that additional makeup
water frequently is required. As water evaporates, the viscosity and flammability of the fluid increases.
Operation at a hazardously low water concentration is difficult.
Water-glycol fluids are compatible with most types of seals and gaskets used with mineral oils, but are
incompatible with certain types of cork, paper, leather and synthetic fiber materials. They also are incompatible
with zinc, cadmium and magnesium, but these materials are seldom used in hydraulic systems.
Synthetic Fluids
Most synthetic hydraulic fluids (HF-D) are one of four types: phosphate esters, chlorinated hydrocarbons,
blends of phosphate esters and chlorinated hydrocarbons and fluids containing other compositions. Most of
these fluids have relatively high specific gravities. Larger diameter or shorter pump suction lines may be
needed to prevent cavitation. Because of the high density, particles do not settle out as easily, making good
filtration necessary.
Recommended temperature limits are 20 to 200F (7 to 93C).
Synthetic fluids are not compatible with natural rubber, Buna, or neoprene seals or hoses. These should
be replaced with fluorocarbon, silicone, butyl rubber, Teflon, or nylon materials. Synthetic fluids also may
attack metal protective paints, lacquers and electrical wiring insulation.

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