COMPRESSOR LUBRICATION: challenges and solutions Ben cat} Sate a Siren Piel) Freee Sete rae inners a nr CO te a eC eae a eee cite ae eas a Recerca erect ss outs Lubrication has a significant influence oa on the behaviour of compressors and their em ee een een eee en compressor lubrication. witha particular focus on rotary SO een eee nS een er eae perianal SnoreThe role of compressors Air as a resource is safe, flexible, clean and convenient. Therefore, air compressors have been used in the industry for over 100 years and have evolved into highly reliable pleces of equipment, which are almost indispensable in many of the applications they serve, Moreover, air compressors play an important role in a range of industries, such as chemical process and heating, ventilation and air conditioning (HVAC). Onshore and offshore rigs typically have several compressors doing various essential duties. Rig air compressors supply air for pneumatic controls throughout the rig. In the case of floating rigs, compressors are used to transfer air from supply ships. Other compressors are used to fill storage tanks that supply the air needed to start large diesel engines and generators on rigs when power is unavailable. Compressors come in a variety of types and sizes, The most common types that are in use today are reciprocating, rotary screw and rotary vane, or ‘positive displacement’ compressors. These increase the pressure of the air by reducing its volume, while rotary centrifugal Js a dynamic compressor that depends on transfer of energy from a rotating impeller to the air. They are further specified by the number of compression stages, cooling method (air, water, oil), drive method (motor, engine, steam turbine) and lubrication, Each type requires a lubricant that Is specific to its application. Figure 1. ExxonMobil SHC Rarus Series alr compressor. Demands on compressor oils Proper attention to the lubricant selection can extend the life of the wearing parts for several years. A high quality industrial air compressor lubricant for pipelines can perform many tasks and can prevent maintenance problems from occurring, It should be able to minimise friction and wear, remove compression heat, work as a sealant to prevent or reduce gas leakage between seal faces and close clearances, shield important parts without causing sludge or deposits and protect the unit’ internal parts from rusting and corrosion, To satisfy these requirements, high performance air compressor oils must have: © Oridation and thermal stability © Low evaporation and coking tendency. © Low foaming. © Good air release. © High rust and corrosion protection © Effective ageing stability © Viscosity — the viscosity requirements vary considerably depending on the type, size and location of the compressor. © Good anti-wear performance for the protection of timing gears where fitted © Low pour point ~ the temperature below which the oil is virtually solid. A typical requirement is a pour point at least -12°C below the lowest start up temperature. © Stability ~ the oil must resist the tendency to form lacquers and sludge. © High flash point for safety reasons © Good demulsibility ~ the oil must be able to separate quickly and completely from the condensate derived from humidity in the air. Challenges for compressor lubrication In recent years, the technology used to generate compressed air has been enhanced. As a result, greater demands are now placed on ait compressor oil. Operators expect long equipment service intervals and, thus, longer life of compressor lubricants il temperatures have risen alongside the reduction in oil volumes: Temperature and ageing resistance of a compressor oil ae of particular importance due to safety and product life considerations. Ifa compressor operates on a temperature that is t00 high for too long the ol will form a thin layer of deposits on the entire inside of the compressor (piping, compressor element «il cooler), The oil cooler will not be able to cool theoll as effectively as it used to, resulting in even higher temperatures and, eventually, an automatic shutdown of the compressor. The high viscosity index of the Mobil Rarus SHC 1020 Series of compressor oils, for example, ensures effective lubrication at high temperatures, These oils, primarily Intended for the lubrication of severe duty rotary screw and vane air compressors, are particularly suited to pipeline operations in the oll and gas sector as these are subjected to high final compression temperatures and where extended oil drain intervals are required, Their high resistance to oxidation and thermal degradation entails, reduced coking deposits, longer oil life, improved filter life and lower maintenance costs. They also provide effective anti-wear and corrosion protection, which enhances equipment life and performance The way lubricating oil is transported to the right lubrication points may also pose challenges. For example, in pressure lubrication that is used for medium and large sized compressors (especially those with high final pressures and capacities), a risk is posed by large amounts, of condensation water collecting in the crankcase as @ result of unsuitable operating conditions and lack of attention. The oil then floats on a layer of water. In the ‘worst case scenario, the oll pump becomes a water pump, having serious results for the compressor. Figure 2. ExxonMobil SHC screw compressor. Lubricating rotary screw compressors Rotary screw compressors work on the principle of alr filling the void between two helical mated screws and their housing. As the two helical screws are turned, the volume is reduced. This results in an increase of air pressure, Most rotary screw compressors inject oil into the bearing and compression area. The reasons are for cooling, lubrication, and creating a seal between screws and the housing wall to reduce internal leakage. Subsequent to the compression cycle, the oil and air must be separated, before the air can be used by the air system. Some rotary screw compressors are flooded by lubricant, others operate with dry screws. When wet, properly cooled oil is required to help absorb the heat of compression, lubricate the rotors and provide sealing, Oil to air or water ta air heat exchangers help to ensure a cool cil supply and minimise carbon deposits on compressor ‘components. Dry screw compressors simply require proper lubrication of the bearings. Improving the bottom line Frequent oil changes every three months) filters and replacement of spare parts of the rotary screw air cooled ‘compressor have proven to be costly to an oil well drilling ‘company in Egypt. In order to reach the optimum drain interval and reduce operating costs, the plant operators have replaced a competitor’ oil with synthetic Mobil Rarus SHC 1026 and started to monitor the used oil through Signum Used Oil Analysis. As a result, the plant has reduced maintenance costs related to spare parts replacement, saving USS31 900 through extended filter and oll life. The oll drain intervals have extended to six months, Overheating and unscheduled downtime have been avoided, and the overall plant productivity has increased due to reduced downtime Conclusion Inthe cil and gas pipelines market specially, contaminated or hot intake air can impair compressor performance and increase maintenance costs. Moisture, dust and other contaminants are also harmful to compressors and can build up on internal components potentially causing premature wear and reducing compressor capacity. Changes in ambient temperature, oil injection and removal also affect the work of compressors. Therefore, using the correct lubricant with the right qualities is erucal forthe reliable and efficient operation of oll and gas plants and machinery. @