Hydraulic Fluid Testing — Condition Monitoring & Contamination Control
Hydraulic fluid testing are the lifeblood of precision machinery: contamination, oxidation, water ingress or additive depletion can quickly lead to wear, valve sticking, pump failure and unscheduled downtime. AGT Labs provides targeted hydraulic fluid analysis focusing on appearance, contamination indicators, water content, residue, corrosivity and compositional changes — supporting reliable fluid condition assessment and maintenance decisions..
We test mineral, synthetic and biodegradable hydraulic fluids across industries including manufacturing, mobile equipment, turbines, marine systems and offshore operations.
The beneficiaries are OEMs, maintenance teams, reliability engineers, fleet operators, offshore and onshore production facilities.
Service Highlights
- Condition assessment using appearance, color, odor, nonvolatile residue, conductivity and corrosion screening.
- Composition and contamination evaluation through GC-based profiling, gum tendency and refractive index checks.
- Support for maintenance decisions with clarity, cleanliness indicators, residue levels and compatibility observations.
Industries We Serve
- Industrial Manufacturing — presses, injection moulders, machine tools.
- Mobile Equipment — construction, mining and agricultural hydraulics.
- Energy & Offshore — subsea actuators, cranes and riser systems.
- Aerospace Ground Support — high-performance hydraulic systems requiring strict cleanliness.
Hydraulic Fluid Testing Matrix
Standard monitoring panels and diagnostic tests for condition-based maintenance and root-cause investigations.
| Test / Parameter | Reference / Method | Technique / Instrument | Notes | Typical TAT |
|---|---|---|---|---|
| Density | ASTM D5002 | Digital Density Meter | Checks hydraulic fluid grade, compressibility and contamination. | 24–48 h |
| Color / Appearance | ASTM D1209 / ASTM D6045 | Visual / Automatic Colorimeter | Detects oxidation, darkening, varnish precursors and contamination. | 24–48 h |
| Copper Strip Corrosion | ASTM D130 / D849 / D1838 | Visual Rating | Assesses corrosivity towards metal components in hydraulic systems. | 24–48 h |
| Carbon Residue | ASTM D524 | Carbon Residue Furnace | Indicates deposit-forming tendency in high-temperature hydraulic systems. | 48–72 h |
| Odor Assessment | ASTM D1296 | Manual Odor Evaluation | Detects abnormal degradation or contamination signatures. | 24–48 h |
| Refractive Index | ASTM D1218 | Refractometer | Screens for fluid mixing, water contamination and additive mismatch. | 24–48 h |
| Electrical Conductivity | ASTM D2624 / ASTM D1125 | Conductivity Meter | Critical for ESD-sensitive hydraulic systems and contamination checks. | 24–48 h |
| Hydrocarbon Composition (Light Ends) | ASTM D2163 | GC-FID | Identifies volatile contamination or improper light-fraction additions. | 48–72 h |
Laboratory Capabilities & Instrumentation
Analytical Systems
Color and appearance assessment, copper strip corrosion rating, refractive index measurement, non-volatile residue determination, conductivity testing, hydrocarbon composition and detailed GC-based analysis.
Reporting & Advisory
- Cleanliness and purity indicators based on color, corrosion behaviour and residue trends.
- Compositional trend summaries using sulfur patterns, hydrocarbon profiles and refractive index shifts.
- Diagnostic support for contamination events and fluid degradation based on accredited test data.
Sampling, Handling & Chain of Custody
Representative sampling is essential for meaningful condition monitoring. Use clean sampling bottles, in-line sample points (with particle counters where possible), and observe contamination-minimising procedures in hydraulic fluid testing.
Sampling Best Practice
- Use in-line particle counters for real-time monitoring if available.
- Collect samples from system midstream (not tank surface) and after stabilization.
- Label with system ID, operating temp, sample point, date/time and operator.
Sample Volumes & Storage
- Typical 100–500 mL for full panel; larger volumes for retention or multiple tests.
- Avoid headspace; keep samples sealed and ship at ambient unless otherwise specified.
- Retain baseline samples for trending and comparative diagnostics.
Quality Assurance, Reporting & Interpretation
COAs include raw values, trending graphs (if requested) and recommended maintenance actions. We provide numeric thresholds linked to OEM/industry guidance and custom alarm levels for asset managers.
- Deliverables: COA, interpretive comments, trend report (optional), and maintenance recommendations.
- Consultation: On-site sampling training and bespoke monitoring program design.
Turnaround Times & Test Packages
| Package | Typical Tests | Typical TAT |
|---|---|---|
| Basic Condition Check | Color, odor, visual water/particulates | 24–48 h |
| Corrosion & Stability Panel | Copper corrosion + carbon residue | 24–72 h |
| Contamination Assessment | Visual particulates, water haze, H₂S headspace, pH of associated fluids | 24–72 h |
| Organic Contaminant Screen | Alcohols / oxygenates and light-end contamination | 48–96 h |
Standards & Accreditation
Hydraulic fluid testing aligns with ISO and ASTM guidance (ASTM D524, ASTM D2624 , ASTM D2163 etc.). AGT Labs operates to ISO/IEC 17025 quality standards; scope and certificates available on request.
FAQs — Hydraulic Fluid Testing
How often should hydraulic fluid be monitored?
What does ISO 4406 cleanliness code mean?
Can you advise on filtration or flushing?
Deliverables & Value-Added Services
- Metal trends and interpretive commentary.
- Trend reporting and fleet dashboards (on request).
- Sampling training, SOP templates and on-site support.
- Urgent testing lanes for critical asset protection.
Summary
AGT Labs’ Hydraulic Fluid Testing provides rapid, actionable insights into fluid condition and contamination — helping maintenance teams prevent failures, extend component life and optimise filtration strategies.