Coolant Management Guide - Silgo

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FUCHS Industrial LubricantsCoolant Management Guide

YOUR PERFECTPRODUCT PARTNERThe continuous monitoring of coolants is essential to ensurethat their performance and quality are maintained. Effectivemonitoring can help to increase machine and fluid life, whileimproving manufacturing efficiency and maximising profitabilityas well as improving safety. However, monitoring the conditionof your fluids needn't be complicated or expensive.Although companies with large lubrication systems will certainlybenefit from implementing the FUCHS CPM, CENT systemsand FLUIDS LIVE, our web based monitoring service (see theTechnical Services Brochure for further information), thosewith smaller systems can use tools, such as refractometers, pHsticks and coolant management charts.There are various monitoring techniques that can be usedto measure a range of factors. Some of these tests may haveto be done in a laboratory, but others are relatively easy andinexpensive to complete. This brief guide gives a few pointerson setting up and operating effective condition-based analysistechniques for coolants.2

THE FUCHS GROUPFUCHS is the world’s largest independent lubricant manufacturer.The Group comprises of 49 operating companies with 33production plants worldwide.In addition to products developed for industry in the UK, wehave access to more than 2,500 industrial FUCHS products fromwithin the Group. Customers can make use of FUCHS’ technicalexpertise and product availability on a global scale, providingaccess to international fluid technology.UK GROUP PROFILEThe headquarters of the UK subsidiary is located at our modern,highly automated production plant in Stoke-on-Trent. Our UKmanufacturing site carries all the necessary approvals requiredincluding AS 9100, ISO 9001, ISO 14001, ISO/TS 16949 andOHSAS 18001.FUCHS is a full line supplier of lubricants and provides customerswith local manufacturing, first-class logistics and specialisttechnical support.RESEARCH & DEVELOPMENTThe FUCHS Group has a very strong focus on R&D with morethan 400 chemists, engineers and specialists in more than 40laboratories worldwide. Our labs are extremely well equippedand audited to the highest levels, having state-of-the-artequipment and highly trained staff with extensive technology andapplication knowledge.Regular dialogue with OEMs, other industry bodies andcomponent suppliers maintains technical advantages. Ourcontinued investment ensures that we are at the forefront oflubricant technology.TECHNICAL SUPPORTWith our industry leading experience in lubrication and chemicalprocesses, FUCHS is able to provide customers with unparalleledproducts and services through focused engineering, administrativeand technical support. Our business support solutions include aUK based customer service team, local customer account managers,as well as experienced technical engineers and product specialists.Every lubrication recommendation schedule and review wecomplete is utterly unique, dedicated to the exact need of theoperation and chosen with the aim of extending service life andto optimise operational efficiency.3

COOLANTMANAGEMENTCompared to other types of lubricants, coolants need extra careand attention to ensure they're kept in good condition. Dirt andcontaminants can have a detrimental effect on the effectivenessof the coolant, therefore good housekeeping practises, effectivecoolant management and high standards of hygiene are essential.BACTERIA AND MICRO-ORGANISMSOne of the most significant causes of reduced fluid quality and lifeis microbial contamination. Water based coolants offer bacteriaan abundant water supply and if not well maintained and controlled, can support microbial growth. Micro-organisms can entercoolant systems in a variety of ways including through tramp oil,organic matter (e.g. food), the water used to mix emulsion andmetal fines. A large presence of bacteria can degrade the technical performance of water miscible cuttingfluids as they createan acidic environment causing the coolant to separate, reducingits lubricity.Bacterially spoiled emulsions can be detected by emulsioninstability or splitting, offensive odours after machine shut down,increased corrosion or rusting, change in coolant colour, drop inpH levels or presence of scum clogging lines or filters.Solution There is no way of preventing bacteria entering thecoolant system, however levels can be kept to a manageable level by avoiding creating a favourable habitat for them to multiply. To help minimise the effect of bacteria, ensure good coolantmanagement practices are in place, including keeping the correctfluid concentration, removing tramp oil, ensuring coolant is keptclean by removing swarf. Scheduled clean outs as required areessential to limit bacteria growth and prolong service life.Coolant care is very important and preferable to post treatmentwith biocides. Post treatment of cooling systems which are out ofcontrol should be minimised as this may lead to releasing endotoxins which have been linked to respiratory disorders.FUCHS personnel can advise on the safe use of biocides whichshould only be considered for use when other control measureshave failed. Extensive use of biocides can increase the risk ofskin irritation and their use must be carefully controlled usingcorrect PPE and safety measures. Biocides should be used at themanufacturers recommended dose to avoid potential for resistantstrains if under dosed.49

WATER QUALITY AND HARDNESSA soluble emulsion may contain 85-98% water, which is whypoor water quality can affect the performance of the fluid; thepurer the water quality, the longer the life of the coolant. Waterhardness varies from very soft (0-20ppm) which increases the riskof foaming, to a very hard 400ppm and above which can causesevere problems in the mixing and stability of the fluid.Solution Where the water quality is generally poor, water softeners, de-ionisation and reverse osmosis systems can be usedto achieve a greater quality of water. Water can also be a majorsource of microbial contamination and therefore fresh drinkingwater quality is preferred when available.TRAMP OILTramp oil, is unwanted, lube oil which has seeped or leaked intothe coolant system, which is the single biggest coolant contamination problem. Tramp oil floats on top of water based emulsions, as it has a lower specific gravity than water. This effectivelyseals off the surface of the sump from air, causing the system todegrade as a result of oxygen deprivation. Anaerobic strains ofbacteria, which do not require oxygen to survive, are encouragedto rapidly multiply in these conditions releasing putrid smellingHydrogen Sulphide. Left untreated, tramp oil can cause quickerfluid degradation, increased corrosion, unstable emulsions andbecome a health hazard to workers.Solution Regular circulation of the fluid can prevent trampoil formation and bacterial growth. Any tramp oil can beseparated and removed using skimmers, tramp oil separators or centrifuges. To eliminate mineral oil leakages into thecoolant system, ensure machines are regularly cleaned, maintained and monitored to detect any leakages in hoses or seals ordefective parts replaced.Well managed systems should have less than 2% tramp oil.SWARFSwarf fines should be removed from the sump on a regular basis.This assists in reducing the risk of corrosion and the removal ofswarf also increases the available sump capacity for the coolant.Removal of fines helps reduce the static zone which can becomecontaminated. It is important to filter the coolant to maintain agood surface finish, cutting performance and to prevent damageto the machines.Removal of fines also helps to reduce the abrasive nature on theskin caused by these sharp particulates.Solution Excess swarf should be separated and removed fromthe fluid, using filtration units or vacuums, as often as possibleand before the machine tool is shut down for a period of time(i.e. between shifts, overnight or prior to the weekend).Well managed coolant samples typically contain less than100ppm/mg per litre of fines.5

COOLANT MONITORINGMONITORING COOLANTCONCENTRATION.Concentration control is of paramount importance and careshould always be taken to maintain the recommended dilutionrates.When the correct concentration is used, end users can saveup to 50% on coolant costs, as well as helping to lower bacteriapopulations and prevent skin problems.The concentration recommended for any water misciblemetalworking fluid is set, by the manufacturer, at a level thatgives maximum performance (EG: 5% 5 parts of water misciblemetalworking fluid concentrate to be mixed with 95 parts ofwater).It is essential that a coolant's strength is checked on a regularbasis - daily checks are recommended.Monitoring concentration can be easily carried out by shopfloor personnel by using a refractometer.MIXING OF WATER MISCIBLEMETALWORKING FLUIDS.Use a mixing system with a clean container to prepare watermiscible coolants.Avoid mixing the fluids in the sump of the machine tool.Automatic mixing systems are available which greatly assist inmixing the coolants. These can be set up to dose accuractlythe desired mix strength to the machine tool.REFRACTOMETERS.A refractometer is a tool that measures the 'refractive index'of a solution; i.e. the volume of oil and water that makes upthe coolant.Refractometers are a quick and convenient way of monitoringcoolant concentration.The refractometer should always be wiped clean betweentesting different emulsions.CALIBRATION.6Lift the Perspex flap and wipe the glass prism clean.Place several drops of clean water onto the glass surface andclose the cover.Look into the refractometer and use the focus ring to create aclear image so that the scale comes into focus in the eye piece.Adjust the small screw on the top of the refractometer untilthe line between the white and blue areas meet at 0 on the scale.The refractometer is now 'zeroed'.Wipe the water off the prism.

REFRACTOMETERMEASUREMENT.REFRACTOMETER READINGSPlace several drops of coolant on the glass surface and closethe cover (the coolant is best taken from the delivery jets.Care needs to be taken to exclude any oil that is floating onthe surface of the coolant, as this will lead to a better readingon the instrument).Look into the refractometer and note the reading on the scale(the reading is taken where the line between the blue andwhite area cut the scale).The actual concentration of the emulsion is obtained by multiplying the scale reading by the factor for the coolant in use.Each product has its own refractometer correction factor,which should always be used when calculating emulsionconcentration to ensure accuracy.New or very clean coolant will give a crisp clear reading.After some time in use, the reading tends to become moreobscure and a diffused area of colour is seen.When the coolant is very dirty and contains a high level oftramp oil, often no reading can be obtained.This view can also be obtained with good coolant and indicatescontamination of the glass slide and Perspex cover with oil,dirt or grease.Cleaning of the glass slide and Perspex cover with soft, nonscratching materials is essential if reliable, repeatable resultsare to be obtained.To calculate concentration: Refractometer Reading x CorrectionFactor Actual Concentration.The correction factor is normally quoted on data sheets.Zero - Mixing waterUsed emulsionClean emulsionVery dirty emulsionRefractometer views7

MONITORINGBACTERIA LEVELSLevels of bacterial contamination should be checked on a regularbasis. A large presence of bacteria can degrade the technicalperformance properties of soluble oil emulsions, as well asincreasing the risk of health problems. Monitoring should beused to confirm your high standard of bacterial control, as well asindicating increased levels of bacteria at an early stage. Measurementcan be done using dip slides; a quick and inexpensive way ofallowing you to maintain low levels of bacteria and take action ifnecessary.DIP SLIDES.A dip slide consists of a plastic carrier coated with a sterile culturemedium, which is dipped into the liquid to be tested.It is then incubated to allow microbial growth and the resultingcolonies are estimated by reference to a chart on which thedensity of the resulting colonies is compared to indicate thelevel of bacterial contamination.Results are expressed in terms of Colony-Forming Units perMillilitre of fluid (CFU/ml).USING A DIP SLIDE.10 310 410 5Loosen the cap on the tube and remove the dip slide from thecontainer, taking care not to touch the surface.Immerse the dip slide into the emulsion being tested - it isessential to ensure that both sides of the slide come into contactwith the emulsion.Enter machine ID and emulsion ID on the container and sendthe dip slide to a laboratory for incubation (@ 30ºC for 48hours) and interpretation.Dip slide samples should be taken carefully avoiding tramp oilcontamination.Used dip slides should be disposed of safely in accordancewith dip slide manufacturers instructions.10 610 7Dip slide comparisons8

EFFECTIVEMONITORINGBACTERIA LEVEL GUIDELINESMONITORING ESSENTIALSThe following values indicate what can be regarded as ‘good’,‘reasonable’ and ‘poor’ levels of bacterial contamination, andwhat action should be taken.Here is a list of things to bear in mind when monitoring:.Good Level 10³ CFU/mlBacteria are being maintained at low levels. No further actionis required.Reasonable Level 103 to 106 CFU/mlReview control measures to ensure levels of bacteria remainmanageable. Risk assessment should specify action to be taken.Biocides and or cleaning may be indicated. If biocides areused, expert advice should be obtained, and the concentrationof biocides should be monitored.Poor Level 106 CFU/mlImmediate action should be taken in line with the risk assessment.Normally at very high levels, draining and cleaning shouldtake place.THE pH SCALE.This is a scale by which the acidity or alkalinity of a solution ismeasured.The scale goes from one to fourteen, with 7 being the neutralpoint (e.g. distilled water).A higher pH (alkali) value indicates that incorrect materials mayhave been put into the machine tool sump and that therecould be an excessive amount of biocide or machine cleanerwithin the system or the coolant concentration could be high.This can result in skin irritation and corrosion.A lower pH (acid) value can indicate high levels of bacterialactivity. This can result in emulsion instability and gummy deposits.MONITORING pH LEVELS.pH levels should be checked at least weekly.Draw up a strategy of things to be tested, frequencies andmethods.Make sure that monitoring is done on a regular basis.Visual monitoring is simple but extremely important - staffshould be vigilant in looking for signs of contamination andchanges in the fluid's appearance and odour.Monitor fines debris counts on routinely tested sample points.Collect and analyse samples from a representative number ofmachines that are not on routine oil analysis, specifically forfines debris and bacteria.Make sure that the equipment used to capture and containthe sample is absolutely clean .If you are taking multiple samples from different systems,take care not to cross-contaminate one fluid sample withanother.Always ensure that fluid systems are not under pressure whentaking samples.Charts are an easy way to record results and the results caneasily be interpreted into graphs - you can then see trendsand changes instantly.Keep records of all tests for several years, as this will help tocreate benchmarks for monitoring.Make sure that results are acted upon.Follow-up any recommendations and record their effect.Coolant systems should be regularly checked for evidence offungal growth. This often occurs in head spaces and abovethe coolant level in the tanks. In case of susspected fungalpresence contact your technical support person for advice onremoval and treatment.For further help and advice contact FUCHS.This is important as a change in the coolant's pH value indicates achange within the coolant itself.There are various methods that can be used to measure pH but theeasiest, on-site method is to use pH strips.USING pH STRIPS.Dip the pH stick into the sample of emulsion.Wait 30 seconds.Compare the colours on the stick with those on the scale on thebox, which will indicate the pH value.9

COOLANTS AND YOURHEALTHCoolants contain a complex mixture of several potentiallyhazardous chemicals. Substances such as emulsifiers, stabilisers,corrosion inhibitors, biocides, fragrances and extreme pressureadditives can all contribute to ill health. The HSE has highlightedthe increased risk of health problems due to contaminated fluidwhich has not been properly maintained and controlled.It is important for manufacturers to be aware of their legalduty of care regarding the protection of the work force fromthe health risks associated with using metalworking fluids. Theprimary aim of the Control of Substances Hazardous to Health(COSHH) regulations is to protect workers from the adversehealth effects of hazardous substances, such as coolants,at work. Under these regulations, manufacturers are legallyrequired to carry out regular and sufficient risk assessments toexamine what, in the workplace, could cause harm to people andassess whether sufficient precautions have been taken to preventharm. The regulations require exposure to metalworking fluidsto be adequately controlled and reduced to a minimum; all nonessential exposure must be prevented.EMPLOYERS SHOULD:.Assess the risks to workers' health and decide what precautionsare requiredPrevent exposure to metalworking fluids or, if not practical,ensure exposure is adequately controlled and minimisedMonitor exposure and carry out any necessary health surveillanceRefer anyone suspected of a work related illness to an occupational health professionalEnsure safety and control measures are regularly checked andmaintained and that all procedures are being observedProvide workers with sufficient information, training andinstruction in the use of control measures and PPE equipmentrequired.EMPLOYEES SHOULD:10Co-operate with employers and follow all training andinstruction givenMake full use of any control measures and PPEReport any defective equipmentAttend and participate in health surveillance programmeswhere necessaryMaintain fluid management procedures and contaminationcontrol measures.

REDUCINGINHALATIONOil mists and vapours are generated when fast movingmachinery vaporises the coolant into the atmosphere.Oil mists and vapours are highly pervasive substances;once airborne, they can remain in the air for lengthy periods before sticking to surfaces, walls and floors.Mist, vapour, smoke and fumes often contain respiratory‘sensitisers’, substances that can trigger an allergic reaction in the respiratory system when inhaled, potentiallycausing respiratory illnesses such as asthma.COOLANT CONTROLVENTILATIONTo reduce the effects of inhalation, the coolant’s volumeand rate of flow to the tool should be controlled to minimise the production of mist or vapour by preventingunnecessary spray and splashing. The fluid should beapplied at the lowest possible pressure and directed atthe tool/ work piece interface; coolant should never flowover unprotected hands. Delivery should be automatically stopped or diverted when not in use. These measureswill also optimise fluid usage and help reduce costs.Adequate ventilation, extraction and air filtration systems, such as Local Exhaust Ventilation (LEV), are alsoeffective in minimising the risk of exposure to oil mistsand vapours as they prevent the accumulation and recirculation of airborne contaminants. Improving naturalventilation, such as opening doors or windows, can helptowards lowering vapour levels.SPLASH GUARDSUSE OF COMPRESSED AIRSplash guards and enclosures can help protect workers fromaccidental splashes and will reduce the extent to whichthe fluid contaminates surrounding surfaces. However, even if machines are completely covered, operatorscan still be exposed to the fluid once the cabinet dooris opened. Using a time delay on doors will allow mistsand vapours to be removed by ventilation. All controlmeasures should be regularly checked, tested and defectiveequipment replaced.It has been shown in studies that the practice of usingcompressed air to remove coolant and swarf frommachined components leads to increased risk of thefluid being aerosolized and deposited onto clothes andthe operators skin. Wherever possible, avoid the useof compressed air and use alternative methods to cleancomponents. Carefully consider the risk, if you must usecompressed air use a low pressure and adopt suitablecontrols to protect your health.11

PROTECTIONFOR SKINCoolants can come into contact with the skin, particularly thehands and forearms, throughout all stages of the manufacturingprocess. Coolants have the potential to cause skin irritation andother contaminants in the fluid can increase the risk of developing skin problems, which is why it is vital to have good coolantmanagement controls in place. The sharp edges of swarf, filingsand other foreign matter suspended in the fluid can cause abrasions and cuts leading to further irritation of the skin.PERSONAL PROTECTIVE EQUIPMENTPPE is designed to minimise contact with coolants and can beeffective in protecting workers from skin irritation. However, PPEshould only be used as a last defence as contact with the coolantcan still occur when PPE is being used by touching the outside, orcontaminating the inside, of clothing when putting on or removing.All PPE should be used in accordance with risk assesments andregularly examined for any tears or holes, cleaned, tested andreplaced.Users should be aware of the increased risk of finger entrapmentin moving parts when wearing gloves. Suitable gloves should beused.HYGIENEGood personal hygiene is vital for reducing the risk of developingdermatitis. A pre-work barrier cream such as FUCHS VelvetoneHand Care Protect should be used in conjunction with PPE andapplied before commencing work, after washing hands and every24 hours to provide an additional layer of protection between theskin and contaminants. Oily rags should not be used to cleanhands; hands, forearms and any other body part that may havecome into contact with metalworking fluids should be regularlywashed with soap and hot water. A reconditioning after-workcream such as FUCHS Velvetone Hand Care Conditioning shouldbe applied after finishing work to help replace and restore theskin’s natural oils.Further information guidance and advice on working safely with Metalworking fluids can be found on theHealth and Safety Executive Web Site : www.hse.gov.uk/metalworking/index.htmFor advice on the safe disposal of metalworking fluids please refer to the UKLA PERA Best Practice Guide:www.ukla.org.uk/publications or contact FUCHS technical experts, Tel: 44 (0) 1782 203 878.Check the web links regularly to ensure the latest advice is followed.12

providing coolantsolutions complementedby excellent technicalsupport and advice.13

YOUR COOLANTMANAGEMENT PARTNERAn effective coolant management schedule should be the cornerstone of any initiativegeared towards improved production efficiency or reducing exposure to metalworkingfluids. FUCHS has developed a unique and flexible Chemical Process Management (CPM)programme that can be customised to serve your specific needs.CPM is a complete lubricant supply package that enables the customer to achievemaximum savings and efficiencies in lubricant usage, whilst maintaining and improvinglevels of production. The CPM programme can assist customers in identifying potentialrisks and planning effective measures of prevention and control. FUCHS provides expertsupport in all areas of fluid supply, distribution, monitoring, maintenance, assessmentand disposal. Full technical support is provided by a dedicated team of production fluidspecialists, with access to extensive laboratory facilities, incorporated into regular sitevisits.As part of our CPM package we offer customers our CENT condition monitoring service.CENT is a state of the art production management tool that indicates the condition of thefluid and equipment by measuring wear trends, additive levels and sources of contamination. Clear and precise feedback is given to the customer in a regular, accurate anddetailed report that highlights status indicators in graphical trend format.Our CPM programmes have been successfully operating for many years; we have a proventrack record in helping companies to develop more efficient and productive workingpractices.As part of our CPM programme you can benefit from:Waste management and equipmentFluid condition monitoring (CENT)Lubrication surveys and schedulesEnvironmental compliance assistanceRationalisation programmesTraining on coolant best practiceMaterials and maintenance managementData management and reporting systemsStock maintenance and managementAssistance with health and safety complianceFluids Live web based recording and reporting toolOur FUCHS team will be happy to provide more information on these, plus the manymore benefits the CPM programme can offer you.14

FLUIDS LIVE: WEB BASEDMANAGEMENT SERVICEFluids Live is an easy to navigate, web based, recording, tracking and reporting tool withintegrated KPI measurements; to give maintenance and production engineers immediateand remote access to the current condition of fluids in use. Fluids Live is an on-lineplatform, offering software free centralised management of data, resulting in noinvestment requirement from users.Information can be updated in as little as 2 hours from the time of collection ofdata giving users all of the information from which to make informed decisions onmaintenance scheduling, production planning and other operational activities.All data collated and stored remains confidential and provides customers with ahistory of fluid usage, condition and concentration.Proactive use of the data will allow for better inventory control, reduced and simplifiedwaste management activity and accurate analysis of fluid consumption by machine,cell or process.The data allows users to plan maintenance strategies more effectively and helpreduce fluid usage expenditure.Each data reporting system is designed and developed by the FUCHS team to thebespoke requirements of the user.Reporting data is broken down to the necessary levels, from company-wide to a specificmachine, illustrating consumption against point of application. Fluids Live allowsmanagement teams to act accordingly based on the data produced.Standard weekly reporting: Shows consumption broken down to the required level.Allows reason to be inputted, e.g. leak, normal consumption, cleanout. This clearlyillustrates the reasons behind consumption figures, providing more information formanagement teams.Exceptions reporting: Highlights high consumption. Ensures leaks do not go unnoticed,providing the opportunity for quick reaction thus reducing consumption costs.Consumption reporting: Illustrates product usage at any level, from department toan individual machine.Automated scheduling: Allows management to schedule workload and edit asrequired – with no limit to the amount of schedules able to be planned.Data capture: Capture data easily via handheld units. Data available to managementas soon as synchronisation is complete. Alternative manual data entry option is available.15

Innovative lubricants needexperienced application engineersEvery lubricant change should be preceded by expertconsultation on the application in question. Only thencan the best lubricant system be selected. We will behappy to advise on the right lubricant for eachapplication and also the range of support serviceswe can offer.FUCHS LUBRICANTS (UK) PLCNew Century Street,Hanley, Stoke-on-Trent,ST1 5HUPhone: 44 (0)1782 203 700Email: 5Contact:

REFRACTOMETER . READINGS. After. . . New or very clean coolant will give a crisp clear reading. some time in use, the reading tends to become more obscure and a diffused area of colour is seen. the coolant is very dirty and contains a high level of tramp oil, often no reading can be obtained. This view can also be obtained with good coolant and .

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