11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Navigation

Search...

Browse:Home / 2012 / August / CompressorLubrication,PartIVA:PositiveDisplacementTypes

4:58pm

August8,2012

4843

CompressorLubrication,PartIVA:PositiveDisplacementTypes

Representingsomeofthemostcomplicatedandcostlyequipmentinaplant,compressors,
alongwiththegasestheyprocess,callforspecializedlubestrategies.
Acompressorisamachinethatraisesthepressureofagasandthendeliversitforuseinavariety
ofapplications,includingthoseassociatedwithcombustion,pneumatic,refrigerationandgas
transmissionprocesses.Themainpurposeofacompressoristoincreasegaspressuretothepoint
whereitcanbeusedinanindustrialfacility.Compressorsareratedbydischargepressureinpsiand
capacityincubicfeet/minute(cfm).
AsshowninFig.1,compressortypesfallintotwomajorgroups:positivedisplacementanddynamic.
Thevarioustypesofunitsinthesetwogroups,alongwiththespecificgasestheycompress(see
TableI),callfordifferentlubricationstrategies.ThatswhyPartIVisdividedintoSectionsAandB.
http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

1/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Thisissuesfocusonpositivedisplacementtypeswillbefollowedbydiscussionsofdynamic
designsandtroubleshootingtechniquesintheSeptember/Octoberissue.
NOTE:Althoughairisthemostcommonlycompressedgasintodaysmanufacturingfacilities,air
compressorspersewillnotbediscussedinthisseries.Lubricationofaircompressorswasthefocus
ofanarticleintheMay/June2009issueofLMT(www.mtonline.com/thibault).

Inpositivedisplacementunits,pressureisattainedbytrappingaspecifiedamountofgasand
convertingittosmallervolume.Reciprocating(recip)units,followedbyhelicalscrewunits,arethe
mostcommonpositivedisplacementdesigns.

Dynamiccompressorsoperateontheprincipleofacceleratingagasbyimpellersorbladesto
increaseitsvelocity.Thegasisthensloweddown,convertingkineticenergyintopotentialenergy,
resultinginanincreaseinpressure.
Typically,positivedisplacementcompressorsreciprocatingdesignsinparticularproducehigher
pressureswhiledynamiccompressors(suchascentrifugalandaxialdesigns)areabletomove
http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

2/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

greatergasvolumes.
Themajorfactorsinvolvedintheselectionofcompressorlubricantsinclude:
Type,sizeandspeedofcompressor
Gasbeingcompressed
Numberofstages
Pressureandtemperatureateachstage
Environment
Typeoflubricationsystem

Reciprocatingcompressors
Operation
Reciprocatingcompressorsincorporateacylinderandpiston,pistonrings,inletvalve,discharge
valveandadriveassemblyconsistingofacrankshaft,connectingrodanddrive,suchasanelectric
motor.Thecompressionprocessbeginswithpistonmovementinthecylindercreatingagreater
volumethatdecreasesthepressure.Thisallowstheinletvalvetoopen,resultingingasflowinthe
cylinder.Oncethepistonreachestheendofitsstroke,theinletvalveclosesandthepistonmovesin
theoppositedirection,reducingthevolumeinthecylinderandcausinggaspressuretoincrease.
Whenthepressureishighenoughtoovercomethegaspressureinthedischargeline,thedischarge
valveopens,allowingthegastoescapeinthedischargeline.Thecycleisrepeatedasthepiston
movesbackandforth.Foreachcycle,gasisdrawnintothecylinder,compressedanddeliveredto
thedischargepiping.Thepistonringsmaintainasealbetweenthepistonandthecylinder,which
letsthegasbecompressedwithoutleakingpastthepiston.
Reciprocatingcompressorshavemanytypesofarrangements,fromnumberofcylinderstostagesof
compression.Inordertoincreasegasdischargevolume,suchcompressorsmayhavemultiple
cylindersthathaveseparateinletlinesbutcommondischargelines.Singlecylindercompressors
areclassifiedaseitherhorizontalorvertical.Themostcommonarrangementsforatwocylinder
compressoraretheVandLshapedlayouts.
Anotherwaytoincreasevolumeinareciprocatingcompressoristocompressthegasonbothfaces
ofthepiston.Thisiscalledadoubleactingcompressor.Throughadiabaticcompression,asthe
pressureonagasincreases,thetemperaturegoesupproportionallyandathighpressurescan
reachveryhighgasdischargetemperatures.Thepressurelimitingfactorinareciprocatingunitis
thetemperatureachievedduringthecompressionprocess.Toachievehigherpressure,twoormore
stagesareused.Thegasiscooledwithanintercoolerbetweenstagesandthenrecompressedto
higherpressure.Thefirststagehasthelargestpistonandcylinderwitheachsuccessivestage
beingsmaller.Figure2illustratesadoubleacting,twostage,Lshapedreciprocatingdesign.(Most
highpressurereciprocatingcompressorsaredoubleacting,multistageandwatercooled.)

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

3/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Lubrication
Lubricationofreciprocatingcompressorsintermsofoiltypeandviscositycanvarywidelybasedon
thetypeofgascompressedandthedesireddischargepressure.Themajorlubricationareasand
componentsonacompressorareasfollows:
CompressorFrame
Mainbearings
Connectingrodbearings
Crossheadbearings
Motorbearings
CylinderRegion
Riderbands
Compressionrings
Packing
Valves

Iftheframebearingsandcylinderareusingthesameoilforlubrication,theoilispumpedfroma
reservoirwheretheoilisfilteredandcooled.Theoilisdistributedtothebearingsintheframebyan
oilpump.Thesameoilisalsoused,bywayofinjectors,tolubricateandsealpistonrings.Inmany
cases,twodifferentlubricantsareused.Theframebearingsdontrequiresyntheticsbecauseofthe
moderateconditions.Highpressure,hightemperatureconditionsmayrequiresyntheticsor
compoundedoilsinthecylinder.Also,higherpressuresrequirehigherviscosities.Aseparateoil
systemisusedtosupplyoiltotheinjectorsforthecylinder.Toomuchoilinthecylindercancreate
problems,suchascarbonizingthevalves.Itisbettertounderlubricatethanoverlubricate.One
quartofoilwilllubricatethesweepofthepistonover10,000,000ft2.Thefollowingistheformulato
http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

4/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

calculatetheoilrequiredinquarts/day.Thisisanaverageamountitcanchangebasedon
operatingconditionsandgasbeingcompressed:

Theinjectorsaresetindrops/minuteandhavetobeadjustedtothesizeofthedroptoachieve
quartsperdaycalculation.Duringcommissioningandruninofnewcompressors,thisamountis
usuallydoubled.CheckwiththeOEMforitsrequirements.
Inmostconditions,framesarelubricatedwithrustandoxidationinhibited(R&O)oil(usuallyanISO
VGof150).Insomecases,anOEMmayrecommendanISO100.
Cylinderlubricationisrelatedtothetypeandpressureofthegasbeingcompressed.Unitsthat
compressinertgasesaretheeasiesttolubricatewithISO150R&Ooilundermoderatepressures
<1000psi.Aspressuresincreaseto5000psi,theresacorrespondingincreaseinviscosityfromISO
150to680.

Fig3.Arotaryscrewcompressordesign.
Hydrocarbonorwetgasescanhavealargedilutioneffectonanoilaspressuresareincreasedoil
viscosityshouldincrease.Polyalkyleneglycols(PAG)areveryresistanttodilutionbyhydrocarbons
(andalsodontformdeposits).Underhigherpressureconditionstheyareanexcellentchoice.
Typically,ISO150220isused.Whendischargetemperaturesapproach300F,syntheticsare
usuallyrecommendedsuchasPAGs,whichdontcausedepositswhenoxidized,anddiesters,
whichhavehighthermalstabilityandexcellentsolvencythatpreventsexhaustvalvedeposits(a
majorproblemathightemperatures).

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

5/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Reactivegasescanposemanyproblemswithregardtolubrication.Inapplicationslikeoxygen
compression,ahydrocarbonlubricantshouldnotbeusediftheresachanceofitcomingincontact
withthegas.Fluorocarbonshavebeenusedinthisservice.Compoundedoilswithsyntheticanimal
fathavebeenusedtoprovideprotectionfromacidiccomponents.Insomecases,engineoilshave
beenusedforthesamereason(theirdetergentpackagesneutralizeacidiccomponents).This
approachisntrecommendedifmoistureispresent.Ifyouareworkingwithreactivegases,consult
yourOEMandlubesupplierforthecorrectsolution.
Screwcompressors
Operation
Rotaryscrewsarepositivedisplacementdesignsthatusescrewshapedrotorsforgascompression.
Themaincomponentsaretheinletandoutletportsandthemainandsecondaryrotor(whichmesh
astheyrotate).Thereisagrooveonthesecondaryrotor,andwhenitpassesthegasinletport,the
gasentersthegroove.Thegasbecomestrappedafterpassingtheinlet,formingagaspocketalong
theentirelengthofthegroove.Thelobethenmesheswiththelobeonthemainrotor.Asthelobes
mesh,thevolumeofthegaspocketisreduced,compressingthetrappedgas.Thegasisreleased
asthegroovepassesbythedischarge.Figure3illustratesarotaryscrewcompressor.
Rotaryscrewcompressorsinbothoneandtwostagedesignscangeneratepressuresupto350
psi.Thetwomajorsubsetcategoriesarewetanddryscrews.Themostcommonoftheseisthe
flooded,orwetscrew,wheretheoilandgascometogetherinthecompressor.Theoilprovidesa
sealtorotatethescrews,whereasthedryscrewhasatiminggeartoregulatethescrewmovement.
(NOTE:Floodedscrewcompressorsarethemaincompressortypeusedforaircompression.)
Lubrication
Thedryscrewcompressoristheeasiesttolubricatebecausethereisnocontactbetweentheoiland
gas.Typically,anR&OISO32100isused,dependingonapplicationandtemperature.
Themostcommonisthefloodedscrew,wherethelubricantisindirectcontactwiththecompressed
gas.Themajorfunctionsofthelubricantaretolubricatebearingsandspeedgearifpresent,cool,
sealtherotorsandpreventrust.Mostfloodedscrewsforaircompressionusesynthetics,ofwhich
polyalphaolefin(PAO)andapolyalkyleneglycol/esterblendarethemajortypes.blend.(NOTE:
PleaserefertomyarticleProperSelectionandMonitoringofCompressorLubricants,publishedin
May/June2009issueofLubricationManagement&Technologyforacomprehensivediscussionon
thelubricationofrotaryscrewaircompressors.)
Floodedscrewshavethesameproblemsasreciprocatingcompressorsinprocessinghydrocarbon
andreactivegasesthatreactwiththelubricant.Thetypicalviscositiesusedare3268.Whena
hydrocarbongasisincontactwithmostlubricants,theviscositywillbeloweredbecauseofdilution.
Therefore,toachievethetargetviscosity,ahigherviscosityfluidwillbeneeded.Thebestlubricant
forthisapplicationisaPAG,whichisdilutedlessthananyothertypeofproduct.Fornormal
applications,mineraloils,PAOsanddiestershavebeenused.Rememberthatreactivegasespose
specialproblemswithregardtolubricants.AlwaysconsultthecompressorOEMandlubesupplier.
http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

6/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Otherpositivedisplacementcompressortypes
Rotarylobe
Rotarylobecompressorsarealsocalledblowers.Theycancompresslargevolumesofgasatlow
pressures.Theyfeaturetwofigure8impellersinacasingthatrotateinoppositedirections.Small
clearancesaremaintainedbetweenthelobeswiththeuseoftiminggears.Thegasistrapped
betweentheimpellerandthecasing.Astheimpellerrotates,successivevolumesofgasarepacked
intheconfinedspaceresultinginanincreaseinpressure.
Lubricationisperformedontheunitsbearingsandtiminggear.EitheranR&O150220oranAW
150220shouldbeused.(NOTE:TheNovember/December2012
issueofthismagazinewillcoverblowersindetail.)
Slidingvane
Aslidingvanecompressorconsistsofacylinder,aslottedrotorandvanesthatfitintherotorslots.
Thevanesarefreetoslideinandoutoftheslotsasfarasthedistancebetweentherotorand
cylinderwalls.Therotorismaintainedoffcentersoacrescentshapedspaceisleft.Centrifugalforce
holdsthevanesagainstthecylinderwallduringoperation.Eachpairofvanesformsgaspocketsof
varyingsize.Wherethedistancebetweentherotorandcylinderisgreatest,thegaspocketisthe
largest.Astherotorturns,thevolumeofthegaspocketsgetssmaller,compressingthegas.Asthe
vanespassthedischargeport,thecompressedgasflowsoutofthecylinder.Thesecompressorsare
small,runquietandrequirelowmaintenanceatlowtomoderatepressures.Theyaresensitiveto
particles.Thevanescontactthecylinderwallsinaboundarylubricationconditionthereforeantiwear
oilsareusedranginginviscosityfrom32150,dependingontheapplication.
Liquidpiston
Thiscompressorhasonlyonemovingpart:arotorwithblades.Thereareopeningsbetweeneach
pairofblades.Thecompressorispartiallyfilledwithwater.Duringoperation,thewaterisspun
outwardbytherotorandformsaliquidringaroundthecasing.Separategaspocketsareformed
betweeneachpairofblades.Sincetherotorismountedoffcenterinthecasing,thegaspocketsare
largenearthegasinletportandsmallnearthedischargeport.Gasentersthegaspocketsasthey
passtheinletport.Thegasbecomestrappedandcompressedbytheliquid,reducingthesizeofthe
gaspocketandproducingtheincreaseinpressure.Atfullcompression,thegaspocketsopening
passesthedischargeport,andthecompressedgasflowsthroughthedischargeline.Liquidpiston
unitsareusedinlowpressureapplications.Therollingelementbearingsaretheonlylubricated
components(withISO3268R&Ooilor,insomecases,anNLGI1or2lithiumgrease.)

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

7/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Basictroubleshootingtechniques
Compressortroubleshootingcallsforastrongknowledgeofmachinecomponentdesign,operating
parameters,lubricationrequirementsandOEMspecifications.Indepthtroubleshootingusually
becomesaoneononeproposition:Withaproblemcompressor,thetroubleshootermusttakea
deeplookintoeachpieceofthepuzzle.Thefollowingpointscompriseabasictroubleshooting
approachforalltypesofcompressors.
Temperature.Changesintemperaturefromanestablishednormisareliableindicatorofchangesin
machinecondition.Dailytemperatureinspectionsshould,atleast,include:suctionanddischargeof
gas,gasinterstagecoolers,afterstagecoolers,lubeoilcoolers,coolingwater,mechanicalseals,
crankcaseandbearingoils.Periodicchecksofbearings,valvesandcylinderheadtemperaturesare
important.
Levels.Liquidlevelsincompressorcomponentsmustbemonitoreddiligently.Correctcrankcase,
bearinghousing,reservoiroillevels,feedratesoncylinderinjectorsandcirculatingoilsystemsmust
bekeptconstant.Compressedgasreceivers,intercoolers,aftercoolersandprocesspipingmustbe
drainedandkeptliquidfree.Freewatershouldbedrainedfromoilreservoirsandoilfilterhousings
daily.

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

8/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Pressures.Allcompressorsaredesignedtooperateinspecificpressurerangesthisisone
governingfactordeterminingwhattypeofcompressorisusedinwhatservice.Pressuredifferentials
betweensuction,interstageanddischargegasesmustbetrackedandvariancesoutofthenorm
investigated.Bearing,mechanicalsealandoilfilterpressuresshouldbechecked,atleastdaily.Air
compressorinletfilterdifferentialpressureshouldbecheckeddaily.
Changesinvibrationorsound.Knocks,pings,rattlesorticksshouldbeinvestigatedassoonas
possibleafterdetection.
Oilanalysisshouldbeconductedonnolessthanaquarterlybasisandonamonthlybasisin
severeservice.Testsshouldinclude:viscosity,particlecounts,wearmetals,watercontentandFTIR
orRulerforremainingusefuloillife.Modificationstothisbasictestslatewillberequired,depending
oncompressortypeandservice.
Troubleshootingspecificsforpositivedisplacementtypes...
Reciprocatingcompressors.Notepressurechangesoutsidethenorm(i.e.,highintercooler
pressuremakessecondstagevalvesorunloaderssuspectlowintercoolerpressurepointstofirst
stagevalvesandunloaders).
Monitorvalvetemperatures(hotonesaretrouble).Checkcoolingwaterinletandoutlettempsfor
efficiency.
Trackcrankcaseoilviscosityonreciprocatinggascompressorsoildilutioniscommon.Whena
recipcompressordevelopsaknockanditsnotcausedbyinsufficientlubrication,itslikelydueto
mechanicalloosenessofbushingsonthewristpins,crossheadsorcranks,orloosefastenerson
foundations,cylinders,headbolts,etc.
Floodedrotaryscrewcompressors.Properfunctioningoftheoilseparatorisoneofthekeysto
longmachinelife.Thelubeoilisexposedtogrossparticleingressionand/orviscositydilutionfrom
beingmixedwiththecompressedairorprocessgas.Theoilseparatormustremovetheseparticles
ortheoilwillsoonbecontaminated.
Trackparticlecountsandwearmetalinthelubeoilandoilfilterdifferentialpressure.
Rotarylobeandliquidpistoncompressors.Theseunitsonlyrequirelubricationfortheirshaft
supportbearings.Troubleshootingandoilanalysiscanbeaccomplishedperthebasicapproach
notesabove.
Slidingvanecompressors.Thesecompressorscanalsobemonitoredviathebasicapproach
above,withtheadditionofweardebrisanalysis,particlecounttrendingandtrackingofoilfilter
differentialpressures.

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

9/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Comingup
PartIVBintheSeptember/Octoberissuewillfocusonlubestrategiesandtroubleshootingtipsfor
dynamic(i.e.,centrifugalandaxial)compressortypes.LMT
RayThibaultisbasedinCypress(Houston),TX.AnSTLECertifiedLubricationSpecialistandOil
MonitoringAnalyst,heconductsextensivetrainingforoperationsaroundtheworld.Telephone:(281)
2500279.Email:rlthibault@msn.com.

Youmayalsolike:
DesigningForStiction,AmongOtherThings
ProcessSafety:TrainOnSafeGasCylinderHandling
EfficientControlOfScrewCompressors
KaeserExpandsCompressorOperationsinGermanyandU.S.
DesigningForStiction,AmongOtherThings
ProcessSafety:TrainOnSafeGasCylinderHandling
[ what's this ]

FollowUs

AboutMaintenanceTechnology
ViewallpostsbyMaintenanceTechnology

BigMoneyTalks:ParsingRenewableEnergyProductionTaxCredits
FromOurPerspective:Using'Nous'ToMakeSenseOfOurSense

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

10/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

0Comments
Recommend

MaintenanceTechnology

Share

Login

SortbyBest

Startthediscussion

Bethefirsttocomment.

ALSOONMAINTENANCETECHNOLOGY

TheBusinessCaseForAssetReliability

TechnologyisforSale,CultureisNot

1comment2yearsago

3commentsamonthago

Roland_Stilesifitjamsforceit,ifitbreaksit

WilliamCorcoranQuotation:Itiseasierto

neededfixinganyway

takeapersonoutofaculturethantotakea
cultureoutofaperson.Bill

BuildingACorporateReliabilityProgram

InformationManagementStrategiesTo
AchieveCollaborativeAssetLife

1comment2yearsago

1comment3yearsago

MichaelIngram HasNovelispublishedits

FacilitatedSelfAssessmentanywhere?Iwould
verymuchliketohaveacopy.

Subscribe d AddDisqustoyoursiteAddDisqusAdd

Search...

bdhodgesThebestALM/EAMsolution(suite)

onthemarkettodayisCATSbyFulcrum
Technologies.Theyareexperts

Privacy

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

11/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

12/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

Backtotop
QuickLinks
Advertise
ContactUs
Events
Products
Subscribe
Videos
Webinars
WhitePapers

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

13/14

11/20/2016

CompressorLubrication,PartIVA:PositiveDisplacementTypesMaintenanceTechnology

RecentPosts
ProgrammableTransmitters,Switches
EmpireisObsessedWithChange
ITTPROServicesLaunchesNextGenPumpSmartPS220ControlAndProtectionSolution
ZebraTechnologiesIntroducesRugged,EnterpriseClassTC5SeriesTouchMobileComputers
RecyclableMoistureBarrier

LatestIssue

Presentedby:

Tweets
Areyouassmartasapumppro?TakeITT's2017WorldofPumpsQuizhttps://t.co/B0mpcJO866That's20weeks/20
questions.Goodluck!#WOPQ4daysago

It'sAlive:RockwellAutomationintroducingFactoryTalkTeamOneAppforinfoaccessandpeercollaborationat
#AutoFair16.2weeksago
FollowmtmagazineonTwitter

2016MaintenanceTechnology.AllRightsReserved.

http://www.maintenancetechnology.com/2012/08/compressorlubricationpartivapositivedisplacementtypes/

14/14