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Compressor Lubrication Best Practices

Heinz P. BlochTags: compressor lubrication

Acompressor 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 formof 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 ComponentsDynamic compressorshave afew keycomponents 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) operatewithout a liquid film separating the faces. On the more conventio nal liquid- lubricated seals, the bearing and

sealing lubricant are often the same.

Figure 2a Figure 2b

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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 OperationThe 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

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Yes

No

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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 pumpsfrom 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 thelube 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 SealsIn 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 OperationsThe 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 oi l 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. Al ternatively, 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

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Heinz P. BlochHeinz Bloch works as a consultant for Process Machinery Consulting. He is the author ofmore than 400 technical papers and similar publications. He has written 17 books onpractical machinery ... Read More

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 LubricantsThe 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.

Machinery Lubrication(5/2003)

About the Author

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