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Lubrication
Proper lubrication is vital to compressor operation and requires special attention in package design. Two
independent systems lubricate a compressor; the frame oil system and the force feed system. The frame oil
system is a pressurized circulating system that supplies oil to the crankshaft, connecting rods, and
crossheads. The force feed system is a high-pressure injection system that supplies small quantities of oil to
the piston rod packings and piston rings.
In a compressor, lubrication:
1. Reduces friction - Decreases energy consumption and heat generation.
2. Reduces wear - Increases equipment life and decreases maintenance costs.
3. Removes heat from the system - Cools moving parts and maintains working clearances.
4. Prevents corrosion - Generally provided by additives rather than the base lubricant.
5. Seals and reduces contaminant buildup - Improves gas seal on piston and packing rings, and
flushes away contaminants from moving parts.
6. Dampens shock - Reduces vibration and noise and increases component life.
Many types of oils exist, some petroleum based, others synthetic. Each oil exhibits different characteristics
that suit it for a specific application.
Lubricant Terminology
VISCOSITY - Measures fluid resistance to flow. It decreases with increasing temperature. In this document,
viscosity is expressed in centistokes (cSt). Proper viscosity is the most important aspect of compressor lub-
rication. FIGURE 5 illustrates viscosity differences between base stock types.
Viscosity can increase with oxidation or contamination by a liquid of higher viscosity or decrease with con-
tamination by hydrocarbon gas condensate or other liquid of lower viscosity. Oil degradation increases vis-
cosity, unless it is multi-viscosity oil (such as SAE 10W40). In multi-viscosity oils, the viscosity improvers
degrade, not the base oil itself.
VISCOSITY INDEX - Indicates the magnitude of viscosity change with respect to temperature. The higher
the viscosity index, the less viscosity decreases as temperature increases.
POUR POINT - Specifies the lowest temperature at which oil flows. It is important in cold weather applic-
ations and in cylinder and packing lubrication with cold suction temperatures.
FLASH POINT - Specifies the lowest temperature at which oil vaporizes to create a combustible mixture in
air. If exposed to flame or high temperature, the mixture flashes into flame and then extinguishes itself. This
is important in high temperature applications where oil may mix with air.
Oil Cooler
An oil cooler is required to remove heat from the frame lube oil. When sizing an oil cooler, consider tem-
perature and flow rate of both cooling medium and lube oil. Insufficient cooling water flow rate is the primary
cause of high oil temperatures. Mount cooler as close to the compressor as possible with piping of adequate
size to minimize pressure drop of both lube oil and cooling medium.
The Application Manual lists required cooling water temperature and flow rate to properly cool oil with Ariel
supplied coolers. The Ariel Performance Program lists oil heat rejection data for each frame in the frame
details section (contact Ariel for details).
Oil Filter
All compressor frames require oil filters to remove particle contamination that can damage equipment and
oil. Contaminants that damage equipment include wear particles from equipment, airborne particles such as
dust or sand, and particulates in new oil. Contaminants that damage oil include oxidized oil components and
air bubbles.
l Ariel filters are not designed for reverse flow often caused by pumping oil out of the compressor through
the filter. This can invert and tear the filter media, sending dirty oil to crankshaft bearings.
l With canister style filters, always drain oil filter housing before element removal or dirty oil will be sent to
crankshaft bearings.
l Keep new filter elements sealed in their original packaging during storage. Visually inspect filter
internal/external surfaces prior to installation. Do not install damaged, corroded, or contaminated filters.
l When using a remotely mounted duplex filter, leave the frame mounted spin-on or canister filter in place
as a polishing filter. At a minimum, leave frame mounted filters in place until they are verified free of solid
contaminants of any size.
JG:A:M:P:N:Q:R:J, KB100, JGH:E:K:T/2/4, KBK:T/2/4, and JGC:D:F/2 compressors ship with simplex,
spin-on, non-bypassing, resin-impregnated filters as standard. Spin-on filters carry a 5 micron nominal and
17 micron absolute rating. The Beta ratings are ß5 = 2 and ß17 = 75. Many spin-on filters fit an Ariel com-
pressor, but very few meet filtration ratings of Ariel filters. Do not use aftermarket filters.
JGE:K:T/6, KBK:T/6, JGC:D:F:B:V/4/6, JGZ:U, and KBB:V:Z:U compressors ship with simplex or duplex
cartridge style pleated synthetic filters as standard. Cartridge filters are rated as 1 micron nominal and 12
micron absolute filters. The Beta ratings are ß1 = 2, ß5 = 10 and ß12 = 75.
Pressure gauges monitor pressure drop across the filter. High differential pressure indicates a plugged filter.
Ariel recommends lube oil filter replacement every 6 months, or 4000 hours, or when oil filter differential pres-
sure at normal operating temperature reaches 10 psid (0.7 bard) for spin-on filters or 15 psid (1.0 bard) for
cartridge filters, whichever comes first. On start-up, differential pressure may exceed the filter replacement
limit until the oil reaches operating temperature. On the same schedule, or with every main oil filter change,
clean the sintered element in the small oil filter of the force feed lubricator.
Oil Heaters
The compressor may need a frame oil heater to meet allowable oil viscosity requirements at start-up (see
“Viscosity” on page 10). One possible heating mode maintains the compressor frame at a minimum tem-
perature so the compressor can start immediately if needed (see TABLE 1). Multiply the coefficients listed in
TABLE 1 by the differential between target oil temperature and ambient temperature to obtain the kilowatt
rating for a heater.
Another mode heats oil from ambient to a minimum temperature prior to starting (see TABLE 2). Multiply the
coefficients listed in TABLE 2 by the rise in oil temperature and divide by target hours to obtain the kilowatt
rating for a heater.
Ariel recommends circulation heaters for all Ariel compressors. JGZ:U:B:V, KBZ:U:B:V units use circulation
heating only. Heated oil should circulate through the filter, bearings, and crossheads as well as the sump.
All Ariel compressors have at least one heater connection; four and six throw frames have two. Maximum
allowable watt density for an immersion heater is 15 W/in2 (2.3 W/cm2 ). This limit prevents oil coking on the
heater element, which reduces heater efficiency and contaminates remaining oil.
TABLE 1 Heat Required to Maintain Minimum Frame Temperature: kW = Ch x ∆T
Viscosity
The minimum allowable viscosity of the oil entering the frame is 16 cSt. Typically, this is the viscosity of ISO
150 grade oil at about 190°F (88°C). See FIGURE 5.
TABLE 4 Oil Viscosity Requirements, cSt
Oil Temperature
Maintain frame inlet oil temperature as close to 170°F (77°C) as possible. Minimum lube oil operating tem-
perature is 150°F (66°C) to drive off water vapor. Maximum allowable oil temperature into the compressor
frame is 190°F (88°C). Higher temperatures increase the oxidation rate of mineral oil. Every 18°F (10°C)
within the operating range doubles the oxidation rate of mineral oil.
For proper operation of the thermostatic control valve, the maximum differential pressure between the hot oil
supply line and the cooled oil return line is 10 psid (0.7 bard).
Oil Maintenance
An oil analysis program is the most effective way to determine frame oil change intervals. Consistent oil ana-
lysis can identify when to change oil on the basis of need rather than a scheduled interval. Depending on ser-
vice, oil analysis can significantly extend oil change intervals.
Install a sampling point between the oil pump and filter at an easily accessible location (KBK:T compressors
ship with an oil sampling valve). Minimize dirt or debris that can collect around it. Use a needle valve to better
control pressurized oil flow.
Collect and analyze oil samples to verify suitability for continued service. Oil analysis should include:
l Viscosity testing at 104°F (40°C) and 212°F (100°C). This verifies that oil has not mixed with cylinder oils
or process gas.
l Particle counting to the latest version of ISO 4406.
l Spectroscopy to determine wear metals, contaminants, and additives.
l FTIR (Fourier Transform Infrared Spectroscopy) to check for oxidation, water or coolant contamination,
and additive depletion. This is more important if the sump oil is not consumed by the force feed system.
ARV Operation
When a force-feed pump encounters a downstream
restriction, pump discharge pressure increases. If
discharge pressure exceeds ARV cracking pres-
sure, the ARV bypasses excess oil back to the low-
pressure inlet side of the pump (FIGURE 8 – High
Pressure). Bypassing oil limits the pressure created
by the pump. The pump will operate in bypass con-
dition until either the divider valve no-flow device
times out due to lack of flow or pressure down-
stream of the pump decreases allowing the ARV to
close (FIGURE 8 – Pressure Relieved).
When the ARV begins bypassing, an indicator pin
protrudes from the top of the ARV indicating an
over-pressure condition. The indicator pin is a “tattle
tale” and remains protruding after the ARV
bypasses oil (FIGURE 8 – Pressure Relieved). Two
bypass conditions are possible: FIGURE 8 ARV Operation
Intermittent blockage downstream of the
pump - A brief condition or one-time event that prevents the shutdown device from timing out and allows the
compressor to continue to operate.
Significant blockage downstream of the pump - A condition of long enough duration to cause the shut-
down device to timeout and shutdown the compressor.
After downstream blockage/restriction removal, the indicator pin can be manually reset by depressing the
indicator pin until it is flush with the ARV housing.
Rupture Disk Assembly
A blow-out fitting with a properly rated rupture disk is installed at the force feed lubricator pump outlet
upstream of the no-flow shutdown. The disk color indicates its burst pressure and should show through the
hole in the fitting. At over-pressure, the disk ruptures and interrupts the oil flow through the rest of the sys-
tem. The no-flow device must shut down the compressor within 3 minutes of oil flow interruption.
Distribution Blocks
Distribution blocks consist of three to seven divider valves and an optional bypass block fastened to a seg-
mented baseplate. O-rings seal between the divider valves and baseplate and between baseplate seg-
ments. Check valves are installed at all lube port outlets.
Divider valves contain metering pistons that discharge a predetermined amount of oil with each cycle in a
single line, progressive lubrication system.
The baseplate contains the divider valve inlet and outlet connections, interrelated passageways, and built-in
check valves. All lubricant piping to and from the distribution block connects to the baseplate. The baseplate
consists of one inlet block, three to seven intermediate blocks, one end block, and three tie rods. The num-
ber of baseplate intermediate blocks determines the number of divider valves allowed. Each distribution
block requires a minimum of three divider valves.
Some systems include primary and secondary distribution blocks. Primary distribution blocks feed two or
more secondary distribution blocks. Connect a no-flow device to the primary distribution block.
Check Valves
Single ball check valves are provided at the oil gallery and divider block outlets. Double ball check valves are
installed at each injection point to prevent reverse leakage and isolate injection points.
Cylinder Lubrication
Cylinder lubrication rates and type are based on operating conditions and gas composition. Several factors
influence cylinder oil dilution/saturation by process gas. TABLE 5 accounts for the following:
1. Process gas composition/Specific Gravity (SG) - usually the higher the SG, the more dilution.
2. Discharge gas pressure - the higher the pressure, the more dilution.
3. Discharge gas temperature - the higher the temperature, the less dilution.
4. Lubricant type - some oils are more prone to dilution than others.
If the Ariel lube sheets specify multiple oil grades or types, use the highest grade oil for all cylinders or recon-
figure the system to use multiple oils.
Natural Gas R & O oil (ISO 150) Cylinder Oil (ISO 220) Cylinder Oil (ISO 460) Cylinder Oil (ISO 680) Contact Ariel
(Water 1.25 x Base Rate w/Compounding w/Compounding w/Compounding
Saturated R & O oil (ISO 220) 2.00 x Base Rate 3.00 x Base Rate
and/or Heavy 1.50 x Base Rate
Hydrocarbons
and SG > 0.7 to Synthetic PAO (ISO 100) Synthetic PAO (ISO 150) Synthetic PAO (ISO 220) Synthetic PAO (ISO 320)
0.8) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100)
1.00 x Base Rate 1.25 x Base Rate 1.50 x Base Rate 2.00 x Base Rate
Natural Gas 0 - 1000 (0 - 69) 1000 - 2000 (69 - 138) 2000 - 3000 (138 - 207) b 3000 - 4000 (207 - 276) b Above 4000 (276) b
(Water
Saturated R & O Oil (ISO 150) Cylinder Oil (ISO 220) Cylinder Oil (ISO 460) Cylinder Oil (ISO 680) Contact Ariel
and/or Heavy 1.25 x Base Rate w/Compounding w/Compounding w/Compounding
Hydrocarbons 1.50 x Base Rate 2.00 x Base Rate 3.00 x Base Rate
and SG > 0.8 to
Synthetic PAO (ISO 100) Synthetic PAO (ISO 150) Synthetic PAO (ISO 220) Synthetic PAO (ISO 320)
0.9)
Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100)
1.00 x Base Rate 1.25 x Base Rate 1.50 x Base Rate 2.00 x Base Rate
Natural Gas Cylinder Oil (ISO 220) Cylinder Oil (ISO 460) Cylinder Oil (ISO 680) Synthetic PAG (ISO 150) Synthetic PAG (ISO 150)
(Water w/Compounding w/Compounding w/Compounding 2.00 x Base Rate 2.00 x Base Rate
Saturated 1.50 x Base Rate 2.00 x Base Rate 3.00 x Base Rate Contact Ariel for Contact Ariel for
and/or Heavy non-synthetic oils non-synthetic oils
Hydrocarbons Synthetic PAO (ISO 150) Synthetic PAO (ISO 320) Synthetic PAO (ISO 460)
and SG > 0.9) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100)
1.25 x Base Rate 1.50 x Base Rate 2.00 x Base Rate
SAE 40 wt. Engine Oil SAE 40 wt. Engine Oil R & O Oil (ISO 220) R & O Oil (ISO 320) Cylinder Oil (ISO 460)
R & O Oil (ISO 150) R & O Oil (ISO 150) Synthetic Ester (ISO 150) Synthetic Ester (ISO 150) w/Compounding
Synthetic Ester (ISO 150) Synthetic Ester (ISO 150) Synthetic PAO (ISO 150) Synthetic PAO (ISO 150) Synthetic Ester (ISO 150)
Synthetic PAO (ISO 100) Synthetic PAO (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAO (ISO 220)
Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) 1.00 x Base Rate 1.00 x Base Rate Synthetic PAG (ISO 100)
1.00 x Base Rate 1.00 x Base Rate 1.00 x Base Rate
Air or gas Synthetic Ester (ISO 150) 1.50 x Synthetic Ester (ISO 150) 2.00 x Synthetic Ester (ISO 150) 3.00 x Synthetic Ester (ISO 150) 3.00 x Synthetic Ester (ISO 150) 3.00 x
mixtures with Base Rate Base Rate Base Rate Base Rate Base Rate
>4% oxygen
content
Natural Gas R & O Oil (ISO 150) Cylinder Oil (ISO 220) Cylinder Oil (ISO 460) Cylinder Oil (ISO 680) Cylinder Oil (ISO 680)
(Water 1.25 x Base Rate w/Compounding w/Compounding w/Compounding w/Compounding
Saturated 1.50 x Base Rate 2.00 x Base Rate 3.00 x Base Rate 3.00 x Base Rate
and CO2
2% to 10%) Synthetic PAO (ISO 100) Synthetic PAO (ISO 150) Synthetic PAO (ISO 220) Synthetic PAO (ISO 320) Synthetic PAO (ISO 320)
Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100)
1.00 x Base Rate 1.25 x Base Rate 1.50 x Base Rate 2.00 x Base Rate 2.00 x Base Rate
Natural Gas 0 - 1000 (0 - 69) 1000 - 2000 (69 - 138) 2000 - 3000 (138 - 207) b 3000 - 4000 (207 - 276) b Above 4000 (276) b
(Water
Saturated Cylinder Oil (ISO 220) Cylinder Oil (ISO 460) Cylinder Oil (ISO 680) Synthetic PAG (ISO 150) Synthetic PAG (ISO 150)
and CO2 w/Compounding w/Compounding w/Compounding 2.00 x Base Rate 2.00 x Base Rate
> 10% to 40%) 1.50 x Base Rate 2.00 x Base Rate 3.00 x Base Rate Contact Ariel for Contact Ariel for
non-synthetic oils non-synthetic oils
Synthetic PAO (ISO 150) Synthetic PAO (ISO 320) Synthetic PAO (ISO 460)
Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100)
1.25 x Base Rate 1.50 x Base Rate 2.00 x Base Rate
Natural Gas Cylinder Oil (ISO 680) Synthetic PAO (ISO 320) Synthetic PAO (ISO 320) Synthetic PAG (ISO 220) Contact Ariel
(Water w/Compounding Synthetic PAG (ISO 100) Synthetic PAG (ISO 150) 2.00 x Base Rate
Saturated 1.25 x Base Rate 1.25 x Base Rate 1.50 x Base Rate
and CO2
> 40%) Synthetic PAO (ISO 150)
Synthetic PAG (ISO 100)
1.00 x Base Rate
Synthetic PAO (ISO 100) Synthetic PAO (ISO 150) Synthetic PAO (ISO 320) Synthetic PAO (ISO 460)
Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) Synthetic PAG (ISO 100)
1.00x Base Rate 1.25 x Base Rate 1.50 x Base Rate 1.50 x Base Rate
Natural Gas Cylinder Oil (ISO 220) Cylinder Oil (ISO 460) Cylinder Oil (ISO 680) Synthetic PAG (ISO 150) Synthetic PAG (ISO 220)
(Water w/Compounding w/Compounding w/Compounding 2.50 x Base Rate 3.00 x Base Rate
Saturated 1.50 x Base Rate 2.00 x Base Rate 3.00 x Base Rate
and H2 S > 40%)
Synthetic PAO (ISO 150) Synthetic PAO (ISO 320) Synthetic PAG (ISO 100)
Synthetic PAG (ISO 100) Synthetic PAG (ISO 100) 2.00 x Base Rate
1.25 x Base Rate 1.50 x Base Rate
Propane 0 - 500 (0 - 35) 500 - 1000 (35 - 69) 1000 - 3500 (69 - 241) 3500 - 5000 (241 - 345) Above 5000 (345)
(Refrigerant) d
SAE 40 wt. Engine Oil SAE 40 wt. Engine Oil Contact Ariel Not Available Not Available
R & O Oil (ISO 150) R & O Oil (ISO 150)
Refrigerant Oil (ISO 150) Refrigerant Oil (ISO 150)
Synthetic PAO (ISO 100) Synthetic PAO (ISO 100)
Synthetic PAG (ISO 100) Synthetic PAG (ISO 100)
0.50 x Base Rate 1.00 x Base Rate
Cycle Time
Lubricant flow rates are measured in seconds per cycle of the distribution block. The calculated break-in and
normal cycle times are stamped on the lubricator box data plate. These cycle times are calculated based on
the gas analysis, operating conditions, and applied speed specified in the compressor order. If gas con-
ditions were not supplied with the compressor order, the data plate/lube sheet rates default to clean, dry,
System Operation
Purging the Force Feed Lube System
1. System must be purged if any connections have been opened, or before initial compressor start-up.
2. Loosen tubing connections at the inlet of the primary distribution block, cylinder, and packing gland
injection points. Also loosen tubing connections at secondary distribution block inlet, if applicable.
3. Connect the purge pump to the pump discharge manifold purge port.
4. Pump clean oil common to the system into the purge port until no air bubbles flow from the tubing
connection at the primary distribution block inlet. Always hold purge pump in a vertical position to avoid
pumping air into the system.
5. While bubble-free oil flows at the primary distribution block inlet, tighten the tubing connection.
6. Continue to operate the purge pump until no air bubbles flow from the tubing connection at the
secondary distribution block inlet, if applicable.
7. While bubble-free oil flows at the secondary distribution block inlet, tighten the tubing connections.
8. Continue to operate the purge pump until no air bubbles flow from the tubing connections at the cylinder
or packing gland injection points.
9. While bubble-free oil flows at the cylinder and packing gland injection points, tighten the tubing
connections.
Lubricant Characteristics
Lubricant Base Stock
Common compressor lubricants include petroleum based oils and synthetic fluids. All lubricant formulations
start with base stock. Lubricant additives improve specific properties such as:
Synthetic Lubricants
Synthetic lubricants are man-made with more consistent, controlled chemical structures than petroleum lub-
ricants. They improve viscosity predictability and thermal stability for much higher viscosity indexes than min-
eral oils. Additives can modify all common lubrication characteristics to meet or exceed mineral oil
performance. Three major synthetic lubricants exist: PAO, Diester, and PAG.
NOTE: Most synthetic lubricants of proper viscosity are acceptable for Ariel compressors.
Check with the lubricant supplier or Ariel before using ANY lubricant, or for questions about lub-
ricant applicability.
l Low Viscosity of about 85-90 cSt at 40°C l Low Viscosity Index of about 70
Lubricant Formulations
A single base stock can yield many different oils by changing additives. Most oils can be formulated with
either a mineral oil or synthetic base. Additives can significantly alter oil physical characteristics and suit-
ability for specific applications. Additives can account for up to 30% of oil volume.
R&O Oil
Rust and oxidation inhibited (R&O) oil is a very good selection for compressor frames and many force feed
systems. This oil is a very simple oil comprised of base stock, corrosion inhibitors, and anti-wear and anti-
oxidant additives. Base stock viscosity determines finished product viscosity.
Engine Oil
Engine oil is formulated for internal combustion engines. It counteracts negative effects of combustion and
helps keep combustion products (soot, water, CO2) away from engine moving parts. It attracts water and
soot and keeps it in suspension until the filter removes it. Some of these additives may prove detrimental to
cylinder and packing lubrication. Engine oil additives may include:
l Detergents to remove deposits around moving parts.
l Dispersants to prevent deposit formation and soot accumulation.
l Corrosion inhibitors to prevent rust and corrosion.
l Antioxidants to neutralize radicals that oxidize oil.
l Anti-wear additives to help prevent metal to metal contact.
l Viscosity improvers (primarily for multi-viscosity oil).
l Pour point depressants to reduce the temperature at which oil solidifies.
l Anti-foam agents to help break up foam from air entrainment.
Ash is not an additive; it is a heavy metal residue left over when oil burns. Some detergents, dispersants,
and anti-wear additives contain heavy metals like calcium, barium, magnesium, phosphorous, zinc, or
sodium. When oil burns on hot engine parts, these heavy metals remain and build a barrier that helps pre-
vent wear such as valve seat recession.
Engine oil works satisfactorily in compressor frames and in many force feed systems for gathering or trans-
mission applications. Engine oil is usually not the best choice for compressor lubrication. Previous exper-
ience, inventory control, or maintenance simplicity may outweigh benefits of a different oil.
Engine oil commonly forms emulsions in the compressor cylinders/piping and can affect performance of
downstream equipment. Detergent additives allow the oil to suspend water resulting in a gel-like mixture
that does not separate into its components. If gas contains enough water, it mixes with the detergents and
emulsifies. Emulsions usually accumulate in downstream equipment such as scrubbers, but also in cylinders
and coolers. To eliminate the problem, completely remove all emulsions and thoroughly clean all equipment.
Re-start compressor using R&O oil or some other appropriate non-detergent oil.
Liquids in Gas
Higher viscosity lubricants or specially compounded lubricants can compensate somewhat for liquids in the
gas stream.
Document contents are proprietary and confidential. They are the property of Ariel Corporation and may not be dis-
closed, reproduced, or used for manufacture in part or in whole without written permission from Ariel Corporation.