Rajan Wilcox
Operating equipment in extreme cold, such as in winter, requires certain considerations to ensure optimal performance and longevity. One such consideration is the impact of low temperatures on hydraulic fluid and diesel fuel. In this context, it is essential to understand whether diesel fuel can be used as hydraulic fluid during winter to mitigate the negative effects of cold weather. While some people have suggested that adding diesel to hydraulic fluid can improve performance in cold weather, there are potential risks to the equipment that should be considered.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Use of diesel fuel for hydraulic fluid in winter | Can reduce viscosity and improve turning forces in hydraulic steering systems, but may damage seals and pumps |
| Impact of cold temperatures on hydraulic fluid | Increase in fluid viscosity, reducing its ability to flow freely and leading to higher differential pressure upstream of the filter |
| Diesel fuel properties | Contains paraffin molecules that can form wax crystals in cold conditions, impacting fuel filters and overall performance |
| Summer vs. Winter Diesel | Summer diesel blends have higher biodiesel content and are more prone to gelling in cold conditions; winter blends have additives to hinder wax crystal formation but lower energy content |
| Cloud Point (CP) | Temperature at which paraffin/wax crystals form in diesel fuel, impacting its appearance and performance |
| Cold Filter Plugging Point (CFPP) | Measures diesel fuel's low-temperature operability by determining the lowest temperature it passes through a fuel filter within a specific time range |
| Impact of diesel in hydraulic systems | Contamination, potential damage to pumps, relief valves, and cylinder seals; dilution of hydraulic oil's paraffinic base stock and reduction in viscosity |
| Recommendations | Use cryogenic hydraulic oils for sub-zero conditions, consult equipment manufacturers, and avoid mixing fuels/oils in multi-use containers |
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What You'll Learn
Diesel in hydraulic tanks can cause issues with relief valves
Diesel fuel is not recommended for use in hydraulic systems due to its adverse effects on various components, including relief valves. Mixing diesel with hydraulic fluid can lead to several issues that compromise the performance and longevity of hydraulic machinery.
One of the critical functions of hydraulic relief valves is to limit system pressure and control the maximum output force of the hydraulic system. These valves achieve this by balancing the hydraulic force with an adjustable spring force. When the pressure reaches a predetermined level, the relief valve opens, releasing heat from the system.
However, the presence of diesel in the hydraulic fluid can disrupt the normal functioning of relief valves. Diesel has a lower viscosity than hydraulic fluid, which can affect the valve's ability to regulate pressure effectively. As a result, the hydraulic system may experience pressure peaks that exceed the system's designed limits. This abnormal pressure increase can lead to the diesel effect, a phenomenon characterised by combustions within the hydraulic system. The diesel effect can cause material damage to pressure relief valves, pump housings, and other components.
Additionally, diesel can weaken the rubber seals in pumps, hoses, valves, and rams. This seal degradation further contributes to fluid leakage and pressure irregularities, exacerbating the risk of the diesel effect and other malfunctions.
To prevent issues with relief valves and ensure the safe operation of hydraulic machinery, it is essential to use the correct hydraulic fluid and avoid mixing it with diesel or other fuels. Proper maintenance, including regular inspection and adjustment of relief valves, is also crucial to maintaining system integrity and avoiding costly repairs.
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The impact of cold on hydraulic fluid and diesel fuel
Cold temperatures can have detrimental effects on the performance and longevity of fluid-powered equipment, such as hydraulic-powered machines and diesel-powered engines. One of the most significant consequences of cold temperatures on hydraulic fluid is the increase in fluid viscosity. As the temperature drops, the hydraulic fluid thickens, impairing its ability to flow freely. This results in elevated differential pressure upstream of the filter, which may cause the machine to enter bypass mode until it warms up and the fluid viscosity decreases.
Diesel fuel is also susceptible to the effects of cold temperatures. Diesel contains molecules of dissolved paraffin, and the amount of paraffin present depends on the blend of fuel. Summer diesel blends, which are more efficient, contain higher levels of biodiesel and, consequently, more paraffin. When exposed to cold temperatures, summer diesel blends are more prone to diesel gelling due to the formation of wax crystals. On the other hand, winter diesel blends are designed to hinder wax crystal formation and perform better in cold conditions.
To mitigate the impact of cold on diesel fuel, it is essential to monitor two critical characteristics: Cloud Point (CP) and Cold Filter Plugging Point (CFPP). CP refers to the temperature at which paraffin or wax crystals begin to form, giving the diesel a cloudy appearance. CFPP measures the low-temperature operability of diesel by determining the lowest temperature at which the fuel can pass through the fuel filter within a specified time range. Diesel filters with optional heaters can be utilised to warm the fuel and reduce wax crystal formation in cold conditions.
While some individuals have suggested adding diesel to hydraulic fluid in cold weather to improve performance, this practice is generally discouraged. Diluting hydraulic oil with diesel can reduce its viscosity, but it also dilutes the paraffinic base stock and diminishes the anti-wear additives and modifiers in the hydraulic fluid. If consistent operation in sub-zero temperatures is required, specialised cryogenic hydraulic oils, such as ISO AW 10 and ISO AW 22, are recommended.
Accidental mixing of diesel and hydraulic fluid due to filling the wrong tank is a common issue. While some machines may continue to operate without apparent problems, others may experience issues with pump and cylinder seals, relief valves, and contaminated hydraulic fluid. In such cases, it is advisable to flush and replace the fluid, as well as seek guidance from service technicians to assess potential damage and necessary repairs.
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The effect of summer and winter diesel blends
Diesel fuel can be used in hydraulic fluid during winter to smoothen operations in cold weather. However, it is not advisable to use diesel in hydraulic tanks for extended periods as it can dilute the hydraulic oil and reduce its viscosity. Diesel contains paraffin, which crystallizes at low temperatures, affecting the performance of hydraulic machinery. Summer diesel blends have higher biodiesel content and are more prone to gelling in cold conditions. Winter blends, on the other hand, contain additives that prevent wax crystal formation, making them more suitable for cold weather.
Summer diesel blends are more efficient fuel sources due to their higher energy content. They are also more cost-effective than winter blends because of the differences in the refining process. However, summer blends have a higher amount of paraffin, which can cause issues in cold temperatures.
Winter diesel blends are designed to prevent the formation of wax crystals, ensuring smooth operations in cold weather. While they have a lower energy content and are less cost-effective, they are crucial for maintaining equipment performance and longevity during winter.
The impact of summer and winter diesel blends extends to their performance in different temperature conditions. Summer blends are suitable for warm temperatures as the paraffin remains dissolved, with little impact on the fuel system. In contrast, winter blends are formulated to withstand colder temperatures by hindering wax crystal formation.
It is important to consider the potential drawbacks of using diesel in hydraulic systems. While it can improve performance in cold weather, it may also lead to reduced fuel efficiency, higher emissions, and increased fuel-related expenses. Additionally, diesel can affect the seals in pumps, hoses, valves, and cylinders, requiring attention to ensure the proper functioning of hydraulic machinery.
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Diesel gelling and how to reduce it
Diesel gelling occurs when the temperature drops, causing the wax crystals in diesel fuel to solidify and clog the fuel filter. This can prevent the engine from getting fuel and cause it to either not run or experience reduced performance. This process is also known as reaching the Cold Filter Plugging Point (CFPP).
To prevent diesel gelling, you can take the following measures:
- Use winterized diesel fuel: Winter blends contain additives that hinder the formation of wax crystals, making them more effective in cold conditions.
- Add anti-gel additives: These additives lower the temperature at which fuel reaches the pour and gel points, reducing crystal formation and improving flow. You should add anti-gel additives every time you fill up, adjusting the amount based on the outside temperature and product potency.
- Maintain a full fuel tank: Keeping your fuel tank more than half full helps reduce the risk of water or condensation collecting and causing diesel fuel to gel.
- Store your vehicle in a garage during cold weather: This can help keep your fuel and engine warmer and reduce the likelihood of gelling.
- Use engine block heaters: These can help warm the fuel as it approaches the engine, reducing the formation of wax crystals.
By taking these preventive measures, you can reduce the risk of diesel gelling and ensure a smoother winter driving experience.
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The impact of diesel on hydraulic seals
The diesel effect occurs when air mixes with hydraulic oil and ignites under pressurisation. This ignition leads to a drastic temperature increase, causing combustion within milliseconds. The high temperatures produced by this process can result in the destruction of seals, as the seals come into direct contact with the fluids. This can lead to traces of burns and charring on the seals, compromising their integrity and functionality.
Additionally, the diesel effect can cause pressure peaks, oil aging, and the formation of combustion residues. These factors can further contribute to the deterioration of hydraulic seals and the overall performance of the hydraulic system. The consequences of the diesel effect may not always be immediately apparent, but they can lead to reduced functionality and potential failures in the system.
To mitigate the impact of the diesel effect on hydraulic seals, it is crucial to minimise the presence of air in the hydraulic circuit. Adequate valves and a well-designed tank and circuit can help reduce the risk of air ingression. Additionally, protecting the seal mounting ring with a phosphor bronze square section can reduce the impact of combustion on the seals, prolonging their lifespan.
While diesel may have some lubricating properties, as observed in certain experiments, its use in hydraulic systems can be detrimental. The primary concern is the potential for combustion and the resulting impact on the integrity of hydraulic seals and other components. Therefore, it is generally recommended to use hydraulic fluid specifically designed for such systems, as it ensures optimal performance, durability, and safety.
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Frequently asked questions
Putting diesel in your hydraulic fluid can thin the oil, which may prevent proper lubrication and hinder reaching the correct pressure. It can also weaken the rubber seals in pumps, hoses, valves, and rams. If you haven't run the machine yet, simply drain the diesel and replace it with hydraulic fluid. If you have run the machine, you may need to flush the system and replace filters.
Cold temperatures cause an increase in hydraulic fluid viscosity. This reduces its ability to freely flow, resulting in higher differential pressure upstream of the filter. This can cause the machine to enter bypass, where unfiltered fluid passes around the filter element, putting critical components at risk.
Tank Optimization can help improve the efficiency of equipment in cold conditions. By maximizing volume utilization and reducing fluid velocity, you can reduce the fluid warmup window, as fluid can reach operating temperature faster.
Some people recommend diluting hydraulic fluid with diesel to reduce viscosity and improve turning forces in hydraulic steering systems. However, this practice is risky and can lead to seal failure and contaminated hydraulic fluid.
