Compressor Lubrication Best Practices

Heinz P. Bloch
Tags: compressor lubrication

A compressor is a type of machine that elevates the pressure of a compressible process fluid, typically
air, or a host of other gases. Dynamic compressors are based on the principle of imparting velocity to a
gas stream and then converting this velocity energy into pressure energy. In contrast, positive
displacement compressors confine a certain inlet volume of gas in a given space and subsequently
elevate this trapped amount of gas to some higher pressure level. The overwhelming majority of
compressors in either the dynamic (axial/centrifugal) or positive displacement (reciprocating and screw-
type) category incorporate moving components.

Nearly all compressors require a form of lubricant to either cool, seal or lubricate internal components.
Only static jet compressors (ejectors) and late 20th- and early 21st-century oil-free machines with rotors
suspended in magnetic or air bearings are exempt from the need for some type of lubrication. This
article deals with the lubrication of dynamic compressors (Figure 1).

Click here to see figure 1.

Key Components
Dynamic compressors have a few key components that require a coolant/lubricant: gears, bearings and
seals. To date, the majority of dynamic compressors continue to utilize oil film-lubricated seals, as
illustrated in Figures 2d, 3a and 3b. Only labyrinth seals (Figures 2a and 2b) or gas-lubricated seals
(Figure 3c) operate without a liquid film separating the faces. On the more conventional liquid-
lubricated seals, the bearing and sealing lubricant are often the same.
Figure 2a Figure 2b

Figure 2c Figure 2d

Figure 2. Traditional Compressor Seal Designs

(Dresser-Roots Co., Connersville, IN)
Figure 3a

Figure 3b
Figure 3c

Figure 3. Modern Compressor Seal Configurations

(Demag-DeLaval, Trenton, NJ)

Lubricating Oil System Operation

The lube oil system (Figure 4) supplies oil to the compressor and driver bearings and to the gears and
couplings. The lube oil is drawn from the reservoir by the pumps and is fed under pressure through
coolers and filters to the bearings. Upon leaving the bearings, the oil drains back to the reservoir.

Click here to see Figure 4

The reservoir is designed to permit circulation of its entire fluid volume between eight to 12 times per
hour. Oil reservoirs often have thermal sensors for monitoring temperature levels during start-up and
constant operations.

Reservoirs also often have oil temperature controls that provide for preheating during cold start-up
conditions and cooling to prevent overheating during peak operating cycles. The reservoir may be
pressurized or vented.

When in operation, the compressor lubricant oil is normally circulated by the main oil pump. An auxiliary
pump serves as a standby. These two pumps generally have different types of drive or power sources.
When both are driven electrically, they are connected to separate supply feeders. On compressors with
step-up gearboxes, the main oil pump may be driven mechanically from the gearbox, and the auxiliary
pump operates during the start-up and run-down phases of the compressor train. Relief valves protect
both pumps from the effects of excessively high pressures. Check-valves prevent reverse flow of oil
through the stationary pump.

Heat generated by friction in the bearings is transferred to the cooling medium in the oil coolers. Air-
cooled oil coolers may be employed as an alternative to water-cooled oil coolers. The former have long
been used in regions where water is in short supply. A pressure-regulating valve is controlled by the
pressure downstream of the filters and maintains constant oil pressure by regulating the quantity of
bypassed oil.

A pressure switch activates the auxiliary oil pump. If the oil pressure falls below a preset limit, a second
pressure switch shuts down the compressor train. Filters clean the lube oil before it reaches the
lubrication points and a differential pressure gauge monitors the degree of fouling (flow restriction) of
the filters.

The flow of oil to each bearing is regulated individually by orifices, particularly important for lubrication
points requiring different pressures. Lube oil for the driver and other mechanical components is taken
from branch lines. For instance, when a hydraulic shaft position indicator is used, it is supplied with oil
from the lube oil system.

Temperatures and pressures are measured at all important locations in the system, including
temperatures from oil sumps, return lines from bearings, gears and other mechanical components.
Temperatures and pressures are often recorded on the suction and discharge sides of each compression
stage to offer the operator a sense of the health of the system. The readings can be taken locally or
transmitted to a monitoring station.

Compressor Seals
In general, the mechanical contact or oil face seal (Figure 3a) employs a spring-loaded stationary carbon
ring in sliding contact with a rotating ring manufactured from high-quality material with a special finish.
This type of seal is also effective when the compressor is at standstill and the oil pumps have been shut
down.

The main components of oil bushing seals (Figure 3b) are two stationary, but radially free-to-move
(floating ring) breakdown bushings with small diametral clearances opposite a shaft sleeve (Figure 3b).
The floating ring clearance controls the flow of the seal liquid cooling the seal.

Floating carbon ring seals (not shown) successfully combine some of the best features of all of the
above. They, too, require seal face lubrication.

Seal Oil System Operations

The seal oil, or seal liquid system (Figure 5) supplies the mechanical contact and floating ring seals with
an adequate flow of seal liquid at all times, correctly ensuring proper function. An effective seal is
provided at the settle-out pressure when the compressor is not running. The seal oil system may be
combined with the lube oil system if the gas does not adversely affect the lubricating qualities of the oil,
or provided the oil made unserviceable by the gas does not return into the oil system.
Click here to see figure 5

There are two methods of combining lube oil and seal oil systems: booster or combined systems. In the
booster system, the oil pressure is raised to the pressure required for lubrication purposes and then part
of it is raised further to the pressure needed for sealing. Alternatively, in the combined system, all the oil
is initially raised to the required pressure and flow, then reduced to system component requirements.
The hardware and operation of each of these types of oil systems are identical or nearly identical.
Mechanical face seals and floating ring seals are supplied with seal oil at a defined differential pressure
above the reference gas pressure (pressure within the inner seal drain). The flow of seal oil is regulated
by a differential pressure-regulating valve, which changes the pressure of the seal oil relative to changes
in system gas pressure or, as shown in Figure 5, by a level-control valve that maintains a constant level
in the overhead tank.

The oil in the overhead tank is in contact with the reference gas pressure via a separate line, with a
static head providing the required pressure differential. In addition, the oil in the overhead tank
compensates for pressure fluctuations and serves as a rundown supply if pressure is lost. If the level in
the tank falls excessively, a level switch shuts down the compressor. A moderate oil temperature is
maintained by a constant flow of oil through the overhead tank.

For the mechanical contact seal system, a regulating valve maintains the reference gas and the seal oil at
a constant differential pressure. As the name indicates, the mechanical contact seal serves as a
mechanical standstill seal when the compressor plant is shut down.

The seal oil is split into two streams in the compressor seals. Most of the flow returns under gravity to
the reservoir. A small quantity passes through the inner seal ring to the inner drain, where it is exposed
to the gas pressure.

This oil, mixed with the buffer gas, flows to the separator system, which consists of a separator and a
condensate trap on each side. The separated gas flows to either the flare stack or to the suction side of
the compressor while the oil flows into a tank for further degassing.

If oil is used as sealing liquid and can be used again, degassing is accelerated by heating or by air or
nitrogen sparging. Sparging units perform on-stream purification of oil which can keep lubricants
serviceable for long time periods. Only if the oil becomes unusable is it led away for separate treatment
or disposal. The quantity of oil passing through the inner drain in a modern centrifugal compressors is
small and ranges from 5 to 50 liters per day on new machines.

Compressor Lubricants
The overwhelming majority of compressors are best served by premium-grade turbine oils with ISO
viscosity grades of 32 or 46. However, there are many different types of compressors and each
manufacturer is likely to recommend lubricants that have been used on a test stand and at controlled
user facilities.

Premium-grade ISO VG 32 turbine oils are used more often than the heavier viscosity grades. The typical
viscosity index is 97, with a pour point around -37C (-35F). Oxidation stability (per ASTM D943) should
exceed 5,000 hours and the flash point (per ASTM D92, COC) should be 206C, or 403F. These
lubricants must provide the following:

Long life without need for changeout

Prevention of acidity, sludge, deposit formation

Excellent protection against rust and corrosion, even during shutdown

Good demulsibility to shed water that enters the lubrication system

 Easy filterability without additive depletion

Good foam control

It is not uncommon to operate these systems for many years on the initial fill of lubricant, in some cases
beyond 30 years. These long-term lifecycles are associated with premium-grade product selection, large
sumps, reasonably good contamination control and the occasional top-off sweetening effect on the oil
in use.

Extended lifecycles on turbine, turbo-compressor and other R&O type oils used in these applications are
also facilitated by the relatively simple additive structure of the product, which minimizes kinds of
complications associated with complex additive systems like those found in EP gear lubricants.

Editors Note
Condensed, by permission, from ISBN 0-88173-296-6, Bloch, Heinz P. Practical Lubrication for Industrial
Facilities. Lilburn, Ga: The Fairmont Press, 2000.

Managing Lubricant Viscosity to Maintain Compressor Health

Robert Kasameyer
Tags: compressor lubrication, viscosity

If youre running one of the approximately 140 working refineries in the United States, the last thing you
need is an unplanned shutdown. But a production standstill is exactly what is at risk if you dont keep an
eye on the viscosity of the lubricating oil used in any of the rotary compressors in the plant, with the
highest risk of these being the gas compressors. One minute all processes are up and running, and the
next theres a bearing failure and production stops.

Its not just the cost of lost production either.

A compressor failure in a single part of the
refinery can cost tens of thousands of dollars
a day in lost revenue, with similar amounts
to rebuild a compressor, and hundreds of
thousands of dollars for a replacement.
Theres also the cost of maintaining spares.

Clearly managing lubricant viscosity is critical

to maintaining compressor health, but it is a
common practice to monitor lubricant
viscosity in each major compressor once a
month by sending a sample to a lab for
testing. For compressors where lubricant
comes in contact with methane and other light hydrocarbon gases, the lubricants viscosity can break
down much more quickly, increasing the risk of failure. Through hard luck, refiners also have found that
real-time temperature monitoring is inadequate to monitor lubricant viscosity.

A major Gulf Coast refinery claims it has solved the problem by moving to real-time monitoring of lube
oil viscosity in critical compressors.

We recognized that in-line viscometers are the best way to know what is happening to the lube oil in
our large screw compressors, says the plant manager. Further, we have found in-line lubrication
viscosity monitoring offers a cost-effective way to keep track of compressor health.

The true measure of the health of a lubricants viscosity can only be gauged when measured in its
natural position with gas vapors dissolved in the lubricant. In addition, monitoring lubricant temperature
isnt sufficient to protect compressor bearings, especially in applications where process starts and stops
can occur.

Whats needed is in-line viscosity monitoring to help provide plant operators with real-time data on
lubricant viscosity. There is a solution for refinery managers working to keep plants online and
producing. New, inexpensive and rugged in-line viscometers are able to monitor real-time changes in
lubricant viscosity, offering a cost-effective way to keep track of compressor health in real time.

Refineries and Compressors

Rotary compressors are used throughout oil refineries in applications ranging from vapor recovery to
gas-processing operations. Screw and scroll compressors make up a significant portion of this
equipment.

Screw compressors use two reciprocal screws to compress gases. Gas is fed into the compressor by
suction and moved through the threads by the rotating screws. Compression takes place as the
clearance between the threads decreases, forcing the compressed gas to exit at the end of the screws.

Scroll compressors, often known as spiral compressors, use two interleaved spiral vanes to move and
compress fluids and gases. Typically found in intermediate and end-product applications, scroll
compressors are valued for their reliability and smooth operation.

The Importance of Lubricant Viscosity

In both types of compressors, lube oil is used to seal the compressor from gas leaks, lubricate moving
parts and manage temperature during operation. The condition of lubricant oil is a critical factor in
extending a compressors bearing life and overall reliability. Monitoring and managing lubricant viscosity
can prevent costly breakdowns due to bearing failure. Viscosity also plays a role in energy efficiency, as
demand for more efficient compressors is driving the use of lower-viscosity lubricants.

A range of lube oils, typically synthetic in composition, is available for use in compressors. Water
resistance, thermal stability, long life, resistance to oxidation and resistance to absorption of process
gases are all important characteristics. While the goal is a lubricant with a long and useful life, harsh
environments, contaminants and even humidity in the refinerys external environment can greatly
reduce lube oils useable lifespan.
Monitoring lube oil viscosity is the best way to prevent bearing wear and compressor failure. While
some plants may monitor as infrequently as once a month, rapid changes in viscosity occur, and the
results can be severe.

Changes in Viscosity and Consequent Risks

Compressor lube oils are formulated to work well and remain stable at high temperatures and
pressures. Hydro-treated mineral oils are used for their low gas solubility (1 to 5 percent). Synthetic
compressor lubricants are used depending on the process and how much gas dilution is present. PAO
(Polyalphaolefin) oils, for example, have excellent water and oxidation resistance. PAG (Polyalkaline
Glycol) oils, which do not readily absorb gases, are used in applications where process gases are
compressed.

Many factors can affect lube oil viscosity. These include oxidation, dilution, contamination, bubbles and
temperature changes.

Oxidation occurs when churning lube oil foams, exposing more oil to surface air and causing oxidation
that lowers viscosity and threatens useful lubricant life.

Dilution is the result when lubricant oil is diluted with gas such as methane, dropping viscosity.

Bubbles form as foaming oil churns against the screws or vanes of the compressor, instantly dropping
the viscosity of the oil.

In contamination, vapors from hydrocarbons being processed can mix with lube oil. This light
hydrocarbon and methane contamination sometimes called a witches brew makes measuring
viscosity challenging.

Significant changes in temperature can occur typically at start-up that affect the viscosity of the
underlying lube oil as well as any contaminants, further aggravating the situation.

A range of compressor failures can result. Bearings, both rotary and thrust, can fail, which in turn cause
wear on the rotor assembly. Replacing bearings is less costly than a total rebuild or replacement. Either
way, the plant faces downtime.

The unpredictability of viscosity changes means monthly checks are not enough to prevent bearing
failure and subsequent plant downtime. Some compressor customers are designing in-line viscometers
into compressors to monitor real-time viscosity changes that happen between standard oil lab analyses,
viewing this preventative approach as an ideal way to ensure bearing life and minimize the costs
associated with unscheduled downtime.

Process Viscometer Approaches

Not all process viscometers are created equal. Several instruments employ an innovative sensor
technology that uses an oscillating piston and electromagnetic sensors. Other process viscometer
technology approaches include falling piston, falling sphere, glass-capillary, U-tube and vibration
designs.

In all cases, plant managers should look for certain characteristics for in-line lubricant viscosity
measurement, such as menu-driven electronic controls, self-cleaning sensors, built-in temperature
detection, multiple output signals, automatic viscosity control, data logging, quick-change memory
settings, security and alerts.

Menu-driven electronic controls can be powerful and easy to use, while a self-cleaning sensor uses the
in-line fluid to clean the sensor as it is taking measurements to reduce unscheduled maintenance.

With built-in temperature detection, the sensor should show temperature as an analog reading.

For automatic viscosity control, look for a sensor that is pre-set but reconfigurable. The sensor should be
able to learn how much control is needed for each fluid setting.

Security and alerts are designed to prevent unauthorized changes and sound an alarm when set points
are reached so operators can take action quickly.

With multiple output signals, the sensors should display temperature and temperature-compensated
viscosity readings.

For process lines that run more than one fluid, quick-change memory settings simplify the process of
changing settings.

In data logging, the date and time code should be automatically logged, creating an audit trail and
simplifying performance and quality-trend measurement.

About the Author

Robert Kasameyer is the president and CEO of Cambridge Viscosity Inc., a global leader in fluid viscosity
measurement. The companys major applications include life sciences and pharmaceuticals as well as oil
and gas exploration, oil analysis, chemical processing and coating. Kasameyer holds a BSME from Tufts
University and an MBA from Harvard University.

Tips for Sampling Oil from Compressors

Noria Corporation
Tags: compressor lubrication
 "Can you describe the best sampling point for a wet-
type screw compressor and the accepted oil cleanliness for this type of machine?"

There are three main objectives for good oil analysis: maximizing data density, minimizing data
disturbance and sampling at the proper frequency. Regardless of the machine type, these three
objectives must be met to receive representative information from your equipment and the oil.

Compressors can be challenging machines for lubricants, as there are often high temperatures, high
pressures and many contaminants intermingling with the oil. One of the biggest factors with compressor
lubrication is the gas that is being compressed. In a wet screw compressor, the oil is flooding the
compression chamber, so any gas being compressed will mix with the oil. Therefore, you need to ensure
that this oil can handle the gas and maintain its lubricating properties.

The majority of these systems are connected to a circulating system. This means that the lubricant flows
through the machine to filters, separators, coolers and perhaps other condition-control devices installed
in the circuit. This provides a variety of locations from which to pull a representative sample. If you can
find an elbow on the main return line prior to the oil draining into the reservoir, this could serve as a
great primary sampling location, as it would provide a snapshot of the entire system.

Many of these circulating systems lubricate more than just the compressor, including the motor, an
associated gearbox and sometimes even different sections of the compressor (bearings, timing gears,
screws, etc.). In these cases, a single sampling point isnt adequate to pinpoint any alarming issues. With
this type of configuration, it is a good practice to install secondary sampling ports after each lubricated
component to help identify any problems being seen at the primary port.

Of course, different systems can handle different amounts of contaminants. Your fluid cleanliness
targets are great key performance indicators to track in order to ensure that the compressor will have a
long service life. Set targets based on the criticality of the equipment. While many compressors will run
well at an ISO code of 17/14/11, if the compressor is highly critical, the target may need to be reduced
to 16/12/10.

Remember, it's always best to balance the manufacturer's recommendations with your own reliability
initiatives when setting targets. In a perfect world, the oil would be as clean as possible to make sure
you aren't inducing wear due to fluid contamination.

Natural Gas Compressors and Their Lubrication



G.E. Totten, G.E. Totten & Associates LLC Roland J. Bishop,Dow Chemical Company
Tags: compressor lubrication, oil oxidation

Natural gas is widely used to heat homes, generate electricity and as a basic material used in the
manufacture of many types of chemicals. Natural gas, like petroleum oil, is found in large reservoirs
underground and must be extracted from these underground cells and transported to processing plants
and then to distribution centers for final delivery to the end user. The gas is moved with the use of many
types and sizes of compressors that collect, pressurize and push the gas though the distribution pipes to
the various processing centers and points of use. The compressors that move the gas are located in
ships and drilling fields, in chemical and process plants, and in the huge maze of pipes that makeup the
distribution network, which brings gas to the market in a pure, useable form. This article explains
various aspects of gas, gas compressor and compressor lubrication, including compressor lubricants,
fluid maintenance and some basic compressor failure analysis guidelines.

Natural gas and petroleum oil formed as a result of the decay of plants and animals that lived on earth
millions of years ago. The decaying matter was subsequently trapped in huge pockets called gas
reservoirs in rock layers underground. These pockets may contain predominantly gas or they may exist
together. It is estimated that the amount of recoverable natural gas within the United States alone is
900 to 1300 trillion cubic feet (Tcf).1

The composition of natural gas at the well head is variable and often contains different compositions of
volatile hydrocarbons in addition to contaminants including carbon dioxide, hydrogen sulfide and
nitrogen. Commercial pipeline natural gas contains predominantly methane and lesser amounts of
ethane, propane and sometimes fractional quantities of butane as shown in Table 1.2

Click Here To See Tables 1 and 2.

For transportation and storage, natural gas must be compressed to save space. Gas pressures in
pipelines used to transport natural gas are typically maintained at 1000 to 1500 psig. To assure that
these pressures are maintained, compressing stations are placed approximately 100 miles apart along
the pipeline. This application requires compressors and lubricants specifically designed for this use.

Gas Compressors
Compressors can be classified into two basic categories, reciprocating and rotary.5Reciprocating
compressors are used for compressing natural gases and other process gases when desired pressures
are high and gas flow rates are relatively low. They are also used for compressing air.

Reciprocating Compressors
Reciprocating compressors compress gas by physically reducing the volume of gas contained in a
cylinder using a piston. As the gas volume is decreased, there is a corresponding increase in pressure.
This type of compressor is referred to as a positive displacement type. Reciprocating compressors are
typically a once-through process. That is, gas compression and lubricant separation occur in a single
pass.

Reciprocating compressors may be further classified as single-acting or double-acting. Single-acting

compressors, also classified as automotive compressors or trunk piston units5, compress gas on one side
of the piston, in one direction. Double-acting compressors compress gas on both sides of the piston.

To consider the lubrication process, it is convenient to divide the parts that need to be lubricated into
two categories, cylinder parts and running parts. Cylinder parts include pistons, piston rings, cylinder
liners, cylinder packing and valves. All parts associated with the driving end (the crankcase end),
crosshead guides, main bearing and wristpin, crankpin and crosshead pin bearings are running parts.

An equation recommended by Scales for estimating the amount of oil to inject into a cylinder for
lubrication is:4

Q = BxSxNx62.8 / 10,000,000

Where: B is the bore size (inches), S is the stroke (inches), N is the rotational speed (rpm) and Q is the
usage rate expressed as quarts of oil per 24-hour day.

The lubricant is then fed directly to the cylinders and packings using a mechanical pump and lubricator
arrangement. Single-acting machines, which are usually open to the crankcase, utilize splash lubrication
for cylinder lubrication. Compressor valves are lubricated from the atomized gas-lubricant in the system.

Compared with cylinder part lubrication, the lubrication of running parts is typically much simpler
because there is no contact with the gas. The equipment manufacturer specifies the required viscosity
grade.

Because gas temperature increases with increasing pressure, if heat is not removed, the lubricant will be
exposed to high temperatures and undergo severe decomposition. Therefore, compressor cylinders are
equipped with cooling jackets. One of the most important roles of the compressor cylinder lubricant is
as a coolant. The coolant is usually water or a water-glycol refrigerant. Although the same lubricant can
be used to cool both the cylinder and the running parts, there are many cases where different lubricants
are used because the cylinder lubricant is exposed to compressed gas at high temperatures. Therefore,
the lubricant should also exhibit thermal and oxidative stability. Table 2 compares compressor operating
temperatures.6

Rotary Compressors
Rotary compressors are classified as positive displacement or dynamic compressors. A positive
displacement compressor utilizes gas volume reduction to increase gas pressure. Examples of this type
of compressor include rotary screw, lobe and vane compressors (Figure 1,7,8,9 Figure 23 and Figure 33).
Figure 1. Screw Compressor

Figure 2. Lobe Compressor

 Figure 3. Vane Compressor

The rotary screw compressor illustrated in Figure 1 consists of two intermeshing screws or rotors which
trap gas between the rotors and the compressor case.10 The motor drives the male rotor which in turn
drives the female rotor. Both rotors are encased in a housing provided with gas inlet and outlet ports.
Gas is drawn through the inlet port into the voids between the rotors. As the rotors move, the volume of
trapped gas is successively reduced and compressed by the rotors coming into mesh.

These compressors are available as dry or wet (oil-flooded) screw types. In the dry-screw type, the
rotors run inside of a stator without a lubricant (or coolant). The heat of compression is removed
outside of the compressor, limiting it to a single-stage operation. In the oil-flooded screw type
compressor, the lubricant is injected into the gas, which is trapped inside of the stator. In this case, the
lubricant is used for cooling, sealing and lubrication. The gas is removed from the compressed gas-
lubricant mixture in a separator. Rotary compressors, such as the screw compressor, continuously
recirculate (1 to 8 times per minute) the lubricant-gas mixture to facilitate gas cooling and separation as
opposed to reciprocating compressors, which are once-through processes.10

In a rotary screw compressor, the lubricant is injected into the compressor housing. The rotors are
exposed to a mixture of the gas and lubricant. In addition to providing a thin film on the rotors to
prevent metal-to-metal contact, the lubricant also provides a sealing function to prevent gas
recompression, which occurs when high-pressure, hot gas escapes across the seal between the rotors or
other meshing surfaces and is compressed again. Recompression causes gas discharge temperatures to
exceed the designed range for the unit. This often leads to loss of throughput and poor reliability.

The lubricant also serves as a coolant by removing heat generated during gas compression. For example,
for rotary screw air compressors, the air discharge temperature may be 80C to 110C (180F to 230F),
accelerating oxidation due to turbulent mixing of the hot air and lubricant.6
In addition to these functions, the bearings at the inlet and outlet of the compressor must be lubricated.
With rotary screw compressors, the lubricant is in contact with the gas being compressed at high
temperatures and it experiences high shearing force between the intermeshing rotors. These are
demanding use-conditions for the lubricant.

A simplified diagram for lubricant flow in a typical rotary screw compressor is shown in Figure 4.8

Figure 4. Lubricant Flow in a Rotary Screw Compressor

The lubricant and gas mixture from the compressor discharge line goes into a gas/lubricant separator
where the compressed gas is separated from the lubricant. After separation, the lubricant is cooled and
filtered, then pumped back into the compressor housing and bearings.

A schematic diagram for a rotary lobe compressor is provided in Figure 2.3 The principle of operation is
analogous to the rotary screw compressor, except that with the lobe compressor the mating lobes are
not typically lubricated for air service. As the lobe impellers rotate, gas is trapped between the lobe
impellers and the compressor case where the gas is pressurized through the rotation of lobes and then
discharged. The bearings and timing gears are lubricated using a pressurized lubricating system or sump.

A rotary vane compressor is schematically illustrated in Figure 3.3 Rotary vane compressors consist of a
rotor with multiple sliding vanes that are mounted eccentrically in a casing. As the rotor rotates, gas is
drawn into areas of increasing volume (A) and discharged as compressed gas from areas of small volume
(B).
As with reciprocating compressors, lubrication of rotary vane compressors is also a once-through
operation. The lubricant is injected into the compressor casing and it exits with the compressed gas and
is usually not recirculated. The lubricant provides a thin film between the compressor casing and the
sliding vanes, while providing lubrication within the slots in the rotor for the vanes. The sliding motion of
the vanes along the surface of the compressor housing requires a lubricant that can withstand the high
pressures in the compressor system.

A dynamic compressor, such as the centrifugal compressor shown in Figure 53, operates on a different
principle.

Click Here to See Figure 5.

Energy from a set of blades rotating at high speed is transferred to a gas, which is then discharged to a
diffuser where the gas velocity is reduced, and its kinetic energy is converted to static pressure. One of
the advantages of this type of compressor is the potential to handle large volumes of gases.

In a centrifugal compressor, the lubricant and gas do not come into contact with each other, which is a
major distinction from reciprocating, rotary screw and rotary vane compressors. The lubricant
requirements are simpler and usually a good rust and oxidation-inhibited oil will provide satisfactory
lubrication of the bearings, gears and seals.
The choice of a compressor lubricant depends on the type and construction of the compressor, the gas
being compressed, the degree of compression and the final outlet temperature. Piston compressors
provide the highest gas pressures and are among the most difficult from the standpoint of cylinder and
valve lubrication and equipment reliability. However, R&O (rust and oxidation inhibited) oil is often
sufficient for the crankcase splash lubrication of a reciprocating compressor.

Rotary compressors with final pressures below 1 Mpa (approximately 145 psi) are less difficult to
lubricate. Because of the potential for vane to cylinder or lobe-to-lobe contact, rotary screw and vane
compressors require the use of an antiwear (AW) oil. The selection of the proper compressor and
application-dependent lubricant with the appropriate physical-chemical properties is vital to a successful
process, and will be addressed fully in the second part of this two-part series of gas compressor and
compressor lubrication issues.

References

1. Estimate obtained from the Natural Gas Week

2. Unit Course 2: For Natural Gas Compressors. Worthington Compression. Corpus Christi, TX.

3. Wills, J. (1980). Chapter 14 - Compressors. Lubrication Fundamentals. Marcel Dekker Inc., New
York, NY, p. 365-394.

4. Unit Course 1 - For Natural Gas Compressors - An Introduction to the Basic Function and
Components of a Gas Compressor Package. Weatherford Compression. Corpus Christi, TX.

5. Scales, W. (1997). Chapter 19 - Air Compressor Lubrication. Tribology Data Handbook, Ed. E.R.
Booser. CRC Press, Boca Raton, FL, p. 242-247.

6. Cohen, S. (1987). Development of a Synthetic Compressor Oil Based on Two-Stage

Hydrotreated Petroleum Basestocks. Lubrication Engineering, Vol. 44, No. 3, p. 230-238.

7. Short, G. (1983). Development of Synthetic Lubricants for Extended Life in Rotary-Screw

Compressors. Lubrication Engineering, Vol. 40, No. 8, p. 463-470.

8. Miller, J. (1989). Synthetic and HVI Compressor Lubricants. J. Synth. Lubrication Engineering,
Vol. 6, No. 2, p. 107-122.

9. Tolfa, J. (1990). Synthetic Lubricants Suitable for Use in Process and Hydrocarbon Gas
Compressors. Lubrication Engineering, Vol. 47, No. 4, p. 289-295.

10. Kist, K., and Doperalski, E. (1979). Brief Introduction to the Screw Compressor. AIChE 86th
National Meeting, Paper 68E.