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There are currently three main types of compressors used for industrial air
compression: reciprocating, rotary screw, and centrifugal. The lubrication
needs and types of lubricants commonly used in these machines, and the
factors that should be considered in evaluating them are different for each
application.
Reciprocating compressor lubrication
Reciprocating compressors can be viewed as two distinct groups: singleacting and double-acting machines.
The lubricant in these units sees relatively severe thermal stress. Due to small
sump sizes, high temperatures, moisture accumulation, and lack of filtration,
fluids with good antiwear properties are normally employed.
Most large, reciprocating compressors are of the double-acting type. A
crosshead isolates the cylinder, where compression occurs, from the sump,
allowing the utilization of two different lubricants to meet the specific needs of
each location. The sump of the double-acting machine is a mild environment
and hydrocarbon oils are typically used there.
Temperatures are typically in the 160_200-F range, with little aeration,
resulting in a very mild oxidizing environment. In this application, a lubricant
may thrive for several years before analysis indicates a need for service.
Rotary screw compressor lubrication
Rotary compressors are compact and efficient (Fig. 2). Small sump sizes
mean a small fluid capacity and increased demands on the fluid. Fluid
replenishment rate is a key factor in the fluid life in these units. There is also a
trend to higher pressures and higher discharge temperatures.
Rotary compressor fluids need to meet several other unique requirements and
critical functions that are different from other types of compressors. Volatility,
or vapor pressure of the fluid should be low, to reduce the carryover rate of
fluid downstream with the air. Corrosion protection is also critical in an
environment where the lubricant is in constant contact with large volumes of
atmospheric air laden with moisture and other contaminants.
Varnish formation must be avoided. Varnish in the orifices and passages
leading to air-end bearings starve the bearings of lubrication, resulting in
catastrophic failure. Varnish on rotors or stators restricts clearances, resulting
in increased frictional losses, energy consumption, and operating
temperature. A varnish coating on the separator shortens separator life, and
increases differential pressure, further eroding energy efficiency.
Centrifugal compressor lubrication
It is critical that the lubricants in these units do not form deposits or varnish on
bearing surfaces. Bearing clearances typically may run as little as 0.001 in.,
and any significant reduction in clearances can result in overheating and
damage to bearings.
The fluid condition of synthetics in centrifugal compressors is easily
monitored. Proper viscosity, viscosity increase, and particulate levels are a
critical concern in these units, as bearing designs and rotor stability are
dependent on proper fluid viscosity.
When not to use a synthetic
What are the goals of an oil analysis program? The most basic goal is to
establish a fluid change interval, and to ensure the fluid in use is still suitable.
Second, and unique to rotary compressors, analysis serves to identify
For the name of a waste lubricant recycler in your area, contact the National
Oil Recyclers Association (216-791-7316.) or visit their website at
What do they do, what does it cost?
Most recyclers collect the fluid, charging a nominal flat fee for pickup plus
about $25 per drum. Some have minimum amounts. Typically, these
companies then filter the fluid, dehydrate it, and sell it as bunker fuel for utility