1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this publication ma
3、y be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA)
4、Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR5277AAEROSPACEINFORMATIONREPORTAIR5277A Issued 1999-09 Revised 2011-06Superseding AIR5227 (R) A
5、erospace Fluid Power - Waste Reduction Practices forUsed Phosphate Ester Aviation Hydraulic Fluid RATIONALEAIR5277 has been updated to revision A for the following reasons: a. Additional information has been provided. Table 1 has been updated, and Table 2 is a new addition. b. Update of references c
6、alled up in the document TABLE OF CONTENTS 1. SCOPE 31.1 Purpose . 32. APPLICABLE DOCUMENTS 32.1 SAE Publications . 32.2 ASTM Standards . 32.3 NAS Standards . 42.4 U.S. EPA Publications. 42.5 European Union Directives . 43. GENERATION OF WASTE HYDRAULIC FLUID . 43.1 System Leakage of Hydraulic Fluid
7、 43.2 Maintenance Activities 43.3 Thermal/Oxidative/Hydrolytic Degradation . 53.4 Contamination . 64. REGULATORY CATEGORIZATION OF USED HYDRAULIC FLUID . 74.1 Trace Heavy Metals 94.2 Chlorinated Solvents . 95. ACCEPTABLE METHODS OF DISPOSAL OF USED HYDRAULIC FLUID . 95.1 Hazardous Waste Incineration
8、 95.2 Energy Recovery Incineration . 9Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR5277A Page 2 of 126. RECOMMENDED PRACTICES TO MINIMIZE FLUID WASTE . 96.1 Hydraulic System Designs 106.2 S
9、torage and Handling of Hydraulic Fluid 106.2.1 Storage of Inventory Stock 106.2.2 Storage of In-Service Fluid . 106.2.3 Solvents, Cleaners and In-Service Hydraulic Fluid 106.3 Recycling and Reuse 116.3.1 Fluid Conditioners . 116.3.2 Basestock Recovery and Reconstitution 116.3.3 Alternate Uses . 117.
10、 SUMMARY 128. NOTES 12TABLE 1 AIRFRAME MANUFACTURERS IN-SERVICE LIMITS FOR AS1241 HYDRAULIC FLUID . 5TABLE 2 TEST METHODS USED FOR AS1241 HYDRAULIC FLUID . 6TABLE 3 U.S. EPA REGULATORY LEVELS FOR CONTAMINANTS 7TABLE 4 U.S. EPA USED OIL FUEL SPECIFICATION1. 8Copyright SAE International Provided by IH
11、S under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR5277A Page 3 of 121. SCOPE This SAE Aerospace Information Report (AIR) covers the generation of used phosphate ester aviation hydraulic fluid (AS1241) that is deemed waste because it doe
12、s not meet in-service limits for use in aircraft. This document also lists the relevant United States Environmental Protection Agency (U.S. EPA) regulations on used hydraulic fluid that are in force at the time of this reports publication. Regulations of other countries as well as those for states a
13、nd municipalities should be consulted prior to initiating any of the waste disposal recommendations listed here. 1.1 Purpose The purpose of this document is to instruct the users of AS1241 hydraulic fluid on appropriate actions for minimizing the generation of waste hydraulic fluid, thereby allowing
14、 for longer service life of the fluid and reducing operating costs associated with the handling and disposal of waste fluid. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicabl
15、e issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulati
16、ons unless a specific exemption has been obtained. 2.1 SAE Publications Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.orgARP598 Aerospace Microscopic Sizing and Counting of Particulate Contamina
17、tion for Fluid Power Systems AS1241 Phosphate Ester Fire-Resistant Aviation Hydraulic Fluid AS4059 Aerospace Cleanliness Classification for Hydraulic Fluids ARP5376 Aerospace Fluid Systems and Components - Methods, Locations and Criteria for System Sampling and Measuring the Solid Particle Contamina
18、tion of Hydraulic Fluids 2.2 ASTM Standards Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA, 19428-2959, Tel: 610-832-9585, www.astm.orgASTM D 445 Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic
19、 Viscosity) ASTM D 974 Standard Test Method for Acid and Base Number by Color-Indicator Titration ASTM D 1217 Standard Test Method for Density and Relative Density (Specific Gravity) of Liquids by Bingham PycnometerASTM D 6304 Standard Test Method for Determination of Water in Petroleum Products, Lu
20、bricating Oils, and Additives by Coulometric Karl Fischer Titration Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR5277A Page 4 of 122.3 NAS Standards Available from Aerospace Industries Asso
21、ciation, 1000 Wilson Boulevard, Suite 1700, Arlington, VA 22209-3928, Tel: 703-358-1000, www.aia-aerospace.orgNAS1638 Cleanliness Requirements of Parts Used in Hydraulic Systems 2.4 U.S. EPA Publications Available from Government Institutes Inc., No. 4 Research Place, Rockville, MD 20850, Tel: (800)
22、 90-9198, www.epa.govU.S. EPA 40 CFR Part 279 - Standards for the Management of Used Oil 2.5 European Union Directives Available from Office for Official Publications of the European Communities, L-2985 Luxembourg, Tel: (352) 29291, http:/publications.europa.euCouncil Directive 94/31/EC of 27 June 1
23、994 amending Directive 91/689/EEC on hazardous wasteCouncil Regulation (EEC) on the Supervision and Control of Shipments of Waste within, into, and out of European Community (EEC259/93) 3. GENERATION OF WASTE HYDRAULIC FLUID Waste hydraulic fluid can be generated in four different ways: a. Excessive
24、 external system leakage b. Normal maintenance activity c. Fluid degradation d. Fluid contamination The release of hydraulic fluid during system operation as well as during maintenance is often unavoidable. Certain actions, however, can be taken to minimize the contamination of hydraulic fluids duri
25、ng storage and thereby effectively extend the service life of the fluid. 3.1 System Leakage of Hydraulic Fluid Commercial aircraft hydraulic systems operate as high as 5000 psi (34.5 mPa) and the potential for leaks always exists. By design, a film of hydraulic fluid external to the hydraulic system
26、 is necessary for the proper operation of specific hydraulic devices. For example, actuator rods are coated with a hydrodynamic layer of hydraulic fluid to enable proper lubrication and sealing. Similarly, pump shaft seals rely on a thin coating and constant replenishment of hydraulic fluid for lubr
27、ication and cooling. When a seal fails, external leakage is excessive and hydraulic fluid is unnecessarily released into the atmosphere. Furthermore, the fluid can pool inside the aircraft thereby creating a source of waste. 3.2 Maintenance Activities Maintenance on commercial aircraft hydraulic sys
28、tems will always release a quantity of hydraulic fluid from the system. In most instances, the released fluid is collected in a catchpan. Also, some fluid is retained in the removed component which may end up in the repair shop. Copyright SAE International Provided by IHS under license with SAENot f
29、or ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR5277A Page 5 of 123.3 Thermal/Oxidative/Hydrolytic Degradation The phosphate ester component of AS1241 hydraulic fluids are susceptible to degradation if exposed to high temperatures, long in-service duration, and/o
30、r contamination. Degradation occurs by any of several chemical mechanisms which either generate acidic species and/or degrade the additive package of the formulated product. High temperature operation and prolonged in-service duration are largely dependent upon the aircraft models hydraulic system d
31、esigns and the specific operators maintenance practices. Contaminants such as water and chlorinated solvents can compromise AS1241 fluid service life by reacting with the phosphate ester to form acids and/or decompose additives that protect the hydraulic components from such effects as rust or elect
32、rochemical erosion.Particulate contaminants provide sites for catalyzing the reactions that form acids. AS1241 hydraulic fluids contain an acid control additive that reacts with the acid species in order to control the fluids acidity to an acceptable level such that corrosive attack on system hardwa
33、re is not a problem. Extreme system operating conditions (225 F/107C) and/or prolonged service time with low fluid topoff rates, however, can result in total depletion of this acid control additive and generate a high acid fluid. Most airframe manufacturers (AFMs) and original equipment manufacturer
34、s (OEMs) have established in-service limits for fluid acidity. These are provided in Table 1. Prolonged operation with an excessively high acid fluid may result in corrosive damage of internal metal surfaces. This corrosion mechanism also generates metal phosphate salts which may precipitate from so
35、lution and possibly inhibit component efficiency or cause additional wear at moving surfaces. TABLE 1 - AIRFRAME MANUFACTURERS IN-SERVICE LIMITS FOR AS1241 HYDRAULIC FLUID CharacteristicBoeingSeattleBoeingLong Beach Airbus Embraer Bombardier Gulfstream Lockheed BAE Fokker Appearance No cloudiness, p
36、hase separation or precipitation, any color is acceptable No cloudiness or precipitation. Color: Blue/purple to gray Specific Gravity 77F/25C0.970 - 1.0660.900 -1.0660.970 -1.0660.995 -1.0660.995 - 1.066 0.995 - 1.02010.995 -1.0660.989 -1.0650.995 -1.0660.999 -1.057Moisture % (max) 0.8 0.7 0.8 0.8 0
37、.8 0.8 1.0 0.6 0.6 Total Acid No. mg KOH/gm (max) 1.521.5 1.5 1.5 1.5 1.5 1.5 0.75 1.0 Kinematic Viscosity 100F/38C, cSt 6.0-12.5 7.0 - 12.0 7.5 - 12.056.0 - 12.5 6.0 - 12.5 6.0-12.5 6.0-12.5 7.0 (min) 6.0 (min) 7.0 (min) ElementalContamination3Calcium ppm max 50 - - - - 50 - - - Potassium ppm max 5
38、0 - - - - 50 - - - Sodium ppm max 50 - - - - 50 - - - Chlorine ppm max 200 200 200 200 200 200 200 200 200 Sulfur ppm max 500 - - - - 500 - - - Particle Contamination #/100ml (max)4Class 9 9 9 9 9 9 8 9 9 5-15 microns 128 000 128 000 128 000 128 000 128 ,000 128 000 64 000 128 000128 000 15-25 micro
39、ns 22 800 22 800 22 800 22 800 22 800 22 800 11 400 22 800 22 800 25-50 microns 4 050 4 050 4 050 4 050 4 050 4 050 2 025 4 050 4 050 50-100 microns 720 720 720 720 720 720 360 720 720 100 microns 128 128 128 128 128 128 64 128 128 Copyright SAE International Provided by IHS under license with SAENo
40、t for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR5277A Page 6 of 12NOTES: 1. Applicable to Global Express. 2. Neutralization number for Boeing 757 Center System is .5 mg KOH/gm (max). 3. Contamination is defined as quantities in excess of those introduced as pa
41、rt of the additive package or basestock. 4. Particle count limits stated per NAS 1638 in accordance with airframe manufacturers documents. SAE recommends AS 4059 when automaticparticle counters are used. 5. Applicable to narrow body aircraft only Chemical testing of the hydraulic fluid can determine
42、 serviceability, using the methods provided in Table 2 or equivalents. If the analyses determine the fluid to be out of any of the AFMs in-service limits, then the fluid should be drained from the system and replaced with new fluid until all in-service limits are met. In most cases, a reservoir drai
43、n and refill is sufficient.In extreme cases, however, a more extensive replacement of system fluid is required. TABLE 2 TEST METHODS USED FOR AS1241 HYDRAULIC FLUID Characteristic Test Method Appearance None specified Specific Gravity 77 F/25 C ASTM D 1217 Moisture % (max) ASTM D 6304 Total Acid No.
44、 mg KOH/gm (max) ASTM D 974 Kinematic Viscosity 100F/38C, cSt ASTM D 445 Elemental Contamination Calcium Inductively Coupled Argon Plasma Analyzer Potassium Inductively Coupled Argon Plasma Analyzer Sodium Inductively Coupled Argon Plasma Analyzer Chlorine Dohrman MCTS-120 Automated Chlorine Analyze
45、r Sulfur Inductively Coupled Argon Plasma Analyzer Particle Contamination #/100ml (max) ARP598 3.4 Contamination The hydraulic fluid that is released from a hydraulic system is generally unsuitable for reintroduction into an aircrafts hydraulic system because of the possibility of contamination whic
46、h may result in operational problems or permanent damage to sensitive components. The only exception to this is described in section 6.3.1, where fluid conditioning equipment may be able to remove certain contaminants to bring the fluid within acceptable limits. Contamination can take two general fo
47、rms, solid particles or chemicals which are typically water, solvents and cleaners, debris from seal wear and internally generated wear particles, and other fluids used in servicing the aircraft. Most AFMs and OEMs have in-service limits on contamination in order to improve reliability and lower mai
48、ntenance costs associated with hydraulic system operation (Table 1). Regular fluid sampling per ARP5376 is recommended to ensure optimum efficiency of system operation. Testing of the hydraulic fluid by an approved testing laboratory can determine contamination levels of in-service fluid. Solid particles can be removed by numerous filtration stages present on both the ground service equipment and aircraft hydraulic system. Filter maintenance m
