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ER-56.

06 ECN: 201900635 VER: 32 - 06-10-2019

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.

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Frame Oil System Components

Oil Connections(see Ariel outline drawing for details) System Components


A1 Packager connection from oil pump 1. Y-Strainer
A2 Packager connection to oil filter 2. Compressor driven oil pump (with safety relief
A3 Oil connection from compressor crankcase (oil valve for pressure regulation, or in models with a
sump) separate regulating valve (7), for relief)
A4 Lube oil compressor inlet connection to gallery tube 3. Thermostatic control valve, 170°F (77°C) nominal
-Oil flows to crankshaft main bearings, connecting rating - required
rod bearings, crosshead pins, and bushings. 4. Pre-lube oil pump - required (shown with oil heating
A5 Pressure regulating valve return connection to oil circuit, when applicable), or auxiliary pump.
sump (when applicable) 5. Optional duplex oil filter
A6 Filter vent return connection to oil sump (when 6. Oil filter
applicable on some models) 7. Pressure regulating valve with overflow return to oil
A7 Oil tubing connections from frame gallery tube to sump (Z:U:B:V only)
top and bottom of crosshead guides to lubricate 8. Oil cooler - required
crossheads. 9. Check valve
A8 Compressor crankcase oil drain (oil sump drain) 10. Heater (when applicable).
A9 Pre-lube/recirculation/heater connections (4) 11. Temperature indicator
12. Pressure indicator (dirty side)
13. Pressure indicator (clean side)
14. Pressure indicator/shutdown connection

FIGURE 1 Standard Frame Lube Oil Schematic

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Oil Connections(see Ariel outline drawing for details) System Components
A1 Packager connection from compressor-driven oil 1. Separate lube oil reservoir (oil sump) - required,
pump vent reservoir to above frame height
A2 Packager connection to oil filter 2. Heater
A3 Packager connection - oil from compressor 3. Y-Strainer - required (supplied unmounted by Ariel)
crankcase 4. Check valve
A4 Lube oil compressor-inlet-connection to gallery tube 5. Compressor driven oil pump (with safety relief
and bearings valve for pressure regulation, or in models with a
A5 Pressure regulating valve return connection to separate regulating valve (14), for relief)
crankcase (when applicable on some models) 6. Oil cooler - required
A6 Filter vent return connection to the crankcase 7. Thermostatic control valve, 170°F (77°C) nominal
(when applicable on some models) rating - required
A7 Oil tubing connections from frame gallery tube to 8. Pre-lube oil pump - required (with oil heating circuit,
top and bottom of crosshead guides to lubricate when applicable), or auxiliary pump
crossheads 9. Optional duplex oil filter
A8 Compressor crankcase oil drain 10. Temperature indicator
11. Pressure indicator (dirty side)
12. Oil filter
NOTE: See ER-93 for further details about dry sump 13. Pressure indicator (clean side)
lubrication systems. 14. Pressure regulating valve with overflow return to
crankcase (when applicable for some models)
15. Pressure indicator/shutdown connection

FIGURE 2 Optional Dry Sump Frame Lube Oil Schematic - Typical

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Oil Strainer
An oil strainer installed upstream of the pump prevents debris from entering the pump and damaging it. Ariel
supplies a 30 mesh (595 microns) on all JG:A:M:P:N:Q:R:J:H:E:K:T, KBK:T, and KB100 compressors and
a 40 mesh (400 microns) strainer on all JGC:D:F:Z:U, KBB:V:Z:U compressors. It is located on the auxiliary
end of the crankcase below oil level. For dry sump frames, the lube oil strainer ships uninstalled from the
factory. The packager installs it in the piping later.

Oil Pump & Regulating Valve


The oil pump constantly supplies oil to all
journal bearings, bushings, and
crosshead sliding surfaces. The crank-
shaft drives it by a chain and sprocket to
provide adequate oil flow to bearings
when the compressor operates at the
minimum speed rating (typically half of
maximum rated speed).
JG:A:M:P:N:Q:R:J:H:E:K:T:C:D:F,
KBK:T, and KB100 compressors main-
tain oil pressure with a spring-loaded
safety relief valve within the pump head FIGURE 3 Typical Lube Oil Pump
(see FIGURE 1). With the unit running at
minimum operating speed and the frame
lube oil at operating temperature, 170°F (77°C), remove the dust cap to expose the safety relief valve adjust-
ment screw and set it so the pressure gauge on the clean side of the oil filter reads 60 psig (4.1 barg).
JGZ:U and KBB:V:Z:U frames maintain oil pressure with a separate regulating valve located downstream of
the lube oil filter (see FIGURE 1). Ensure the pressure relief valve on the main lube oil pump is fully closed.
With the unit running at minimum operating speed and the frame lube oil at operating temperature, 170°F
(77°C), set the separate regulating valve so the pressure gauge on the clean side of the oil filter reads 60
psig (4.1 barg).
When installing a new oil pump on a compressor or after maintenance on an existing oil pump, Ariel recom-
mends priming the pump (wetting the gears with oil) before start-up to ensure proper operation. Upon com-
pressor start-up after oil pump replacement, oil pressure should immediately reach 50-60 psi. If oil pressure
fails to reach 50-60 psi immediately, shut down the compressor and correct the problem. Dry oil pump gears
sometimes contribute to the problem.

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).

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Oil Temperature Control Valve
The lube oil system requires a ther-
mostatic valve to control compressor oil
temperature. A thermostatic valve is a
three-way valve with a temperature sens-
itive element. As the oil heats, the sensing
element opens the third port in the valve.
Ariel recommends a thermostatic valve
with a 170°F (77°C) element. Install the
valve in mixing mode to more directly con- Thermostatic control valve configuration may vary from this schematic
trol oil temperature into the frame (see depending on valve size. Valve connections A-B-C are marked on the
FIGURE 4). valve.
FIGURE 4 Thermostatic Valve in Mixing Mode

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.

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Compressor Pre-lube System
Ariel compressors must be pre-lubed anytime the crankshaft is turned and prior to starting. Ariel strongly
recommends an automated pre-lube system to extend driveline component life.
Ariel requires automated pre-lube systems for compressors that meet any of the following criteria:
l Electric motor driven compressors.
l Unattended-start compressors, regardless of driver type.
l Compressor models JGC:D:F:Z:U:B:V and KBK:T:Z:U:B:V.
See FIGURE 1 for pre-lube circuit design.
NOTE: The pre-lube return into the frame must be upstream of the oil filter.
For on-demand compressor applications, the pre-lube pump can circulate oil continuously through the bear-
ings while on standby.
Ariel requirements are based on a pre-lube pump sized for 25% of frame oil pump flow to ensure oil flow to
bearings, bushings, and oil-filled clearances prior to turning or start-up (see the appropriate ER-96.4.x doc-
ument for frame oil pump flow rates).
The following statements depend on oil supply and sump viscosities, which depend on oil temperature. Oil
supply temperature at the filter head or frame oil gallery is not always a true representation of total oil sump
temperature. See FIGURE 5 to determine oil viscosity based on temperature.
l During a cold start of the unit when oil supply viscosity is greater than 50 cSt, pre-lube pressure should be
30 psig (2.1 barg) at the oil gallery for a minimum of 2 minutes prior to turning or starting.
l During a hot re-start of the unit when oil supply viscosity is less than 50 cSt, pre-lube pressure should be
20 psig (1.4 barg) at the oil gallery for a minimum of 2 minutes prior to turning or starting.
NOTE: A 10 to 15 minute pre-lube is required after:
l Any major drive line maintenance
l The main lube oil system is drained
l Oil filter replacement
Instrumentation: Automated pre-lube systems require a start permissive logic and instrumentation to sat-
isfy the minimum required pressure and duration at the oil gallery inlet.
It is highly recommended that the compressor low oil pressure shutdown be Class B. Inhibited time shall be
no longer than 10 seconds after idle speed is achieved on gas engines or start initiation for electric motors.
If the compressor fails to achieve 45 psig (3.1 barg) oil pressure within 10 seconds after reaching engine idle
speed or electric motor start initiation, ensure shutdown and correct the cause. Repeat pre-lube before each
start attempt.
NOTE: If a compressor fails to start or shuts down at start-up due to low oil pressure, DO NOT
re-start until the cause is corrected.

Compressor Pre-lube for CNG Applications


The normal minimum prelube pressure requirement is 30 psig (2.1 barg) for 2 minutes for continuous duty
compressors. In CNG applications, the compressors can start and stop as much as 50 to 100 times a day.
This special service demands exceptions to normal pre-lube and cold weather starting requirements.
NOTE: The requirements below apply only to JGM:P:N:Q/2 and KB100 compressors in CNG
applications. No other frames or applications are exempt from normal pre-lube requirements.

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1. The minimum pre-lube pressure is 30 psig (2.1 barg) for at least 30 seconds.
2. The minimum oil temperature to pre-lube and start is 30°F (-1°C) when using a PAG type oil that is
acceptable per TABLE 1-1, or 50°F (10°C) when using a non-PAG type oil such as a PAO or mineral oil
that is acceptable per TABLE 1-1. The compressor must have an oil temperature sensor to ensure this
low oil temperature permissive is met. Maximum allowable oil temperature into the crankcase is 190°F
(88°C).
3. The low oil temperature start limit must be no less than the oil temperature required for adequate
viscosity to load the compressor. The maximum viscosity to load is 1000 cSt.
4. Ambient temperatures below 0°F (-18°C) require a standalone circulating auxiliary lube oil heating
system for the compressor. In extreme cold, an immersion heater is inadequate. Maintain oil
temperature between at least 70°F to 100°F (21°C to 38°C).
5. A small bypass line downstream of the circulating heating system that sends oil directly into the frame
sump will help flow sufficient oil to build and maintain heat in the compressor. The bypass line must be a
small diameter so the pre-lube pump can build and maintain adequate pressure. A bypass pressure
relief valve may instead be used to maintain pre-lube pressure and sufficient oil flow through the system
independent of oil viscosity. See FIGURE 1.

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

Heater Coefficient (Ch), kW/°F (kW/°C)


Model
2 Throw 4 Throw 6 Throw

JGM:P:N:Q, KB100 0.0086 (0.0155) --- ---

JG:A 0.0094 (0.0170) 0.0179 (0.0322) 0.0261 (0.0470)

JGW:R:J 0.0147 (0.0265) 0.0289 (0.0520) 0.0419 (0.0754)

JGH:E:K:T, KBK:T 0.0252 (0.0454) 0.0492 (0.0886) 0.0731 (0.1316)

JGC:D:F 0.0392 (0.0706) 0.0722 (0.1300) 0.1044 (0.1880)

JGZ:U, KBZ:U 0.0534 (0.0961) 0.0944 (0.1700) 0.1319 (0.2374)

JGB:V, KBB:V --- 0.1295 (0.2331) 0.1768 (0.3182)

TABLE 2 Heat Required to Warm Cold Frame and Oil: kW = Ch x ∆T / ∆t

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Heater Coefficient (Ch), kW-h/°F (kW-h/°C)
Model
2 Throw 4 Throw 6 Throw

JGM:P:N:Q, KB100 0.0275 (0.0495) --- ---

JG:A 0.0352 (0.0634) 0.0818 (0.1472) 0.1347 (0.3425)

JGW:R:J 0.0591 (0.1064) 0.1212 (0.2182) 0.1832 (0.3298)

JGH:E 0.1368 (0.2462) 0.2962 (0.5332) 0.4526 (0.8147)

JGK:T, KBK:T 0.1494 (0.2689) 0.3024 (0.5832) 0.4526 (0.8147)

JGC:D:F 0.2684 (0.4831) 0.5614 (1.0105) 0.8074 (1.4533)

JGZ:U, KBZ:U 0.4496 (0.8093) 0.8900 (1.6020) 1.2421 (2.2358)

JGB:V, KBB:V --- 1.4176 (2.5517) 2.0224 (3.6403)

Oil System Cleanliness


Clean the compressor frame oil piping system and components of all foreign matter such as sand, rust, mill
scale, metal chips, weld spatter, grease, and paint. Use proper cleaning procedures with proper cleaners,
acids, and/or mechanical cleaning to meet cleanliness requirements. Ariel recommends flushing all oil-pip-
ing systems with an electric or pneumatic driven pump and filtered, clean production oil. Ariel thoroughly
cleans all compressor frame cavities prior to assembly and test runs compressors with a filtered closed loop
lube system.
NOTE: Ariel recommends not disturbing lube oil piping downstream of the installed oil filter.
Contaminants that enter this piping or open ports flush into the bearings causing catastrophic
damage. If contamination is suspected in the supply piping downstream of the oil filter or in the
oil gallery, remove the supply piping and thoroughly clean both the piping and gallery. Before
performing this work, contact Ariel Technical Service for best practices and procedures. To
remove or alter piping, cover the inlets to the oil gallery, the ends of the piping, and the filter out-
let so no contaminants enter. Before reinstallation, chemical and mechanical cleaning is
required. Flush the pipe in accordance with Ariel cleanliness requirements (see TABLE 3).
Prior to start-up, flush all compressors installed with an electric or pneumatic powered pre-lube pump and
less than 50 feet (15 m) of oil piping as outlined below. Include cooler oil passages in the flushing loop. While
oil systems for compressors without an electric or pneumatic powered pre-lube pump and less than 50 feet
(15 m) of oil piping must be clean, oil flushing is desirable, but not required.
For all compressors with oil piping systems greater than 50 feet (15 m), cleaning and flushing must result in a
cleanliness level to ISO-4406, Grade 13/10/9 and/or NAS-1638, Class 5 (see TABLE 3), prior to start-up.

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TABLE 3 Oil Flush Cleanliness
1. Prior to assembling lube oil piping, remove scale, weld Requirements
slag, rust and any other matter that could contaminate lube
oil. Confirm: ISO-4406 GRADE 13/10/9

l Complete and closed lube oil system. Particle Size


Grade Particles
µm/ml Oil
l Crankcase filled to the correct level with appropriate oil. Requirement Allowed
Sample
l Proper and correctly installed lube oil filters. /13 Greater than 4 40 to 80

l Operational and viewable oil pressure transducer or /10 Greater than 6 5 to 10


gauge, oil filter differential-pressure transducers or
/9 Greater than 14 2.5 to 5
gauges, and oil temperature RTD or indicator.
2. Start pre-lube pump. Record oil pressure, oil filter
differential-pressure, and oil temperature. Minimum oil NAS-1638 GRADE 5
pressure is 30 psig (2.1 barg) for effective flushing. Do not Particle Size Range Grade 5 Maximum
exceed 90 psig (6.2 barg). µm/100ml Oil Sample Particles Allowed
3. Flush continuously for one hour. Oil filter differential- 5 to 15 8,000
pressure must not increase more than 10% of measured oil
15 to 25 1,424
pressure into the filter. Record the oil pressure, oil filter
differential pressure, and oil temperature every 15 minutes. 25 to 50 253
Oil temperature increases of more than 10°F (5.5°C)
50 to 100 45
during an hour of flushing invalidate the system cleanliness
test, due to oil viscosity change. Over 100 8

4. After one hour of pre-lube flushing, if differential pressure


or temperature increases exceed the limits above, continue
flushing. If the lube oil filter differential pressure exceeds change filter limits, stop the pre-lube pump and
change the oil filter. To ensure system cleanliness, re-set time and continue flushing until the compressor
achieves a continuous hour of flushing within differential pressure and temperature increase limits.
See ISO-4406 "International Standard - Hydraulic fluid power - Fluids - Method for coding level of con-
tamination by solid particles" and/or NAS-1638 "National Aerospace Standard, Aerospace Industries Asso-
ciation of America, Inc. - Cleanliness Requirements for Parts Used in Hydraulic Systems" for complete
information. Use a competent oil lab for sample testing. To flush the entire oil system see .

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Frame Oil System Operation
Frame Lubricant
In the compressor frame, Ariel recommends ISO 150 grade paraffinic mineral oil that provides oxidation,
rust, and corrosion inhibition, and anti-wear properties - commonly called R&O oil. SAE 40 weight engine oil
is also acceptable, but contains many unnecessary additives.
In limited circumstances and with prior approval from Ariel, cold weather installations may use multi-viscosity
oils in the compressor frame if the oil supplier certifies the oil as shear stable. The viscosity of shear stable oil
degrades less through use. Most oil suppliers certify oil as shear stable if viscosity degrades less than a cer-
tain percentage in specific tests. As a result, multi-viscosity oils are subject to a 30% to 50% shorter life than
single straight grade oils.
Synthetic lubricants are acceptable in a compressor frame provided they meet operating viscosity require-
ments outlined in TABLE 4. Compounded lubricants are prohibited in the frame.

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

Max. Max Max Viscosity into Min Viscosity into


Frame Viscosity Viscosity Compressor at Compressor at
to START to LOAD Operating Temp. Operating Temp.

JG:A:M:P:N:Q:R:J:H:E:K:T, 3,300 1,000 60 16


KBK:T, KB100

JGC:D:F 2,000 1,000

JGZ:U, KBZ:U:B:V 2,000 350

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FIGURE 5 Viscosity vs. Temperature Graph of Different Lubricants

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Oil Pressure
The factory sets normal pressure on the discharge side of the oil filter at 60 psig (4.1 barg) for compressors
tested mechanically complete (inspector tag displayed). If factory tested as mechanically incomplete (no
inspector tag), the packager sets normal oil pressure at initial start-up to 60 psig (4.1 barg) at the lower of the
frame or cylinder rated speed, or driver speed at normal operating temperature. Adjust the oil pressure after
the filter to 60 psig at minimum operating speed and normal operating temperature.
Ariel uses the pump safety relief or separate lube oil pressure regulating valve to regulate pressure into the
compressor. If oil pressure into the compressor at minimum operating speed and normal operating tem-
perature does not read about 60 psig (4.1 barg), adjust the pump safety relief or separate lube oil pressure
regulating valve. With compressor running at minimum operating speed, turn the adjustment screw clock-
wise to increase oil pressure, or counter-clockwise to decrease it. The compressor requires a 45 psig (3.1
barg) low oil pressure shutdown for protection.
Z:U:B:V ONLY: For compressors with a separate lube oil pressure regulating valve, adjust the pump safety
relief valve to full pressure and regulate oil pressure with the separate regulating valve.
NOTE: If oil pressure drops below 50 PSIG (3.4 barg) when crankshaft speed equals or exceeds
minimum rated operating speed, find the cause and correct it.

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.

Cylinder and Packing Lubrication


The cylinder lubrication system injects lubrication into cylinder bores and packings. The system consists of
an oil supply, an oil filter, a force feed lubricator pump, divider blocks, pressure indicators, check valves, and
flow monitoring shutdown devices. The system is progressive; each piston in the divider block must

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complete a cycle before the system cycles again. This type of system offers better lubrication precision and
eases monitoring.

Oil Supply Filter


An in-line oil filter is required upstream of the force feed lubricator pumps. When frame lube oil is used for cyl-
inder lubrication, the provided compressor filtration system is adequate. For separate force-feed lube oil sup-
plies, the packager must install a filter. Ariel recommended filtration is 5 micron nominal. Ariel supplies a
secondary strainer/filter at the pump inlet.

Force Feed Lubricator


The force feed lubrication system oils the compressor cylinders and piston rod packings. Oil flows to the suc-
tion side of the force feed lubricator pump directly from the pressure side of the frame lubrication system, or
from an overhead tank. A self-contained oil reservoir oils the force feed lubricator worm gear and cam. The
force feed lubricator sight glass shows the reservoir oil level.

1. Auto-Relief Valve (ARV)


2. ARV Manifold
3. Priming Stem
4. Pump Plunger Stroke
Adjustment Screw
5. Lock Nut
6. Lubricator Oil Fill Connection
7. Sight Glass
8. Mounting Flange Capscrews
(4)
9. Drain Plug
10. Purge/Vent Connection
11. Pump Outlet to Distribution
Block
12. Inlet to ARV
13. Lubricator Overflow
14. Force Feed Lubricator
Sprocket
15. O-ring
16. Inlet Header
17. Pump Inlet from Header
18. Rupture Disk Assembly

FIGURE 6 Typical Force Feed Lubricator

Auto-Relief Valve (ARV)


An auto-relief valve (ARV) is a mechanical valve that protects force-feed lubrication systems from over-pres-
sure conditions. Unlike a rupture disk assembly, the ARV is reusable and does not expel oil onto the com-
pressor skid.

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1. Spring Barrel 5. Spring 9. Pressure Pin 13. E-Clip
2. O-ring 6. Spring Piston 10. Intermediate Barrel 14. ARV Outlet
3. Washer 7. O-ring Retainer 11. ARV Inlet (Bypass Port)
4. Indicator Pin 8. Manifold 12. Adapter
FIGURE 7 Auto-Relief Valve Components

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.

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Pressure Gauge
Pressure gauges are installed on all distribution blocks for system monitoring and troubleshooting.

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.

Over-Pressure Pin Indicator (Optional)


Over-pressure indicators install on the front face of divider valves. If an outlet port exceeds the specified lub-
ricant pressure, a pin emerges from the front of the indicator, identifying the over-pressured line.

Fluid Flow Monitor and Cycle Indicators (see ER-56.07)


Balance Valves
Balance valves reduce system problems such as bypassing, no-flow switch errors, or blown rupture disks in
high differential pressure distribution block applications. Balance valves add pressure to distribution block
discharge ports to minimize differential pressure across the 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.

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Flushing Oil (Optional)
Ariel recommends cylinder flushing oil for sour gas services with 100 ppm and greater H2S content. Flushing
oil provides corrosion protection for the suction valve bodies and springs. Ariel supplies distribution blocks to
inject oil into the cylinder nozzle on the inlet pulsation vessel. Flushing oil lines are tubed to the end of the
crosshead guide. The Packager provides lube lines from the end of the guide to the suction pulsation vessel
cylinder nozzle. An atomizer for flushing lube injection can be constructed of a thermowell with an 1/8” hole
drilled in the tip.

Common Oil Supply


FIGURE 9 shows the force feed lube system installation when compressor frame lube oil is also used for cyl-
inder and packing lubrication.

1. Frame Oil Gallery


2. Single Ball Check Valve
3. Sintered Bronze Filter (if applicable)
4. Force Feed Lubricator Pump
5. ARV or Rupture Disk
6. Pressure Gauge
7. Divider Valves/Distribution Block
8. Fluid Flow Monitor No-Flow Timer
Shutdown Switch
9. Double Ball Check Valve
10. Top Cylinder Injection Point
11. Bottom Cylinder Injection Point
12. Packing Injection Point

FIGURE 9 Force Feed Lubric-


ation System Common Oil Sup-
ply

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Independent Oil Supply
When cylinders and packing require oil
different from frame oil, the force feed lub-
ricator system requires an independent
oil supply system (see FIGURE 10). An
elevated tank must supply pressurized
force feed lube oil at a minimum of 1 psig
(0.07 barg) to the force feed pump inlet
manifold.
To prevent force feed oil from con-
taminating compressor frame oil, dis-
connect lubricator box overflow tubing
from compressor frame and direct it to a
suitable drain system.
Independent force feed lube systems
require oil with a viscosity below 1100
cSt at the lubricator pump inlet (e.g. ISO
320 at 73°F (23°C), contact lube supplier
about specific lubricants). Possible ways
to ensure force feed pump is fed oil dur-
ing suction stroke: FIGURE 10 Force Feed Lubrication
System Independent Oil Supply
l Increase pipe and fitting size from tank
to force feed pump.
l Heat the oil.
l Heat trace and insulate the line from the tank.
l Pressurize the supply tank (tank must be designed for pressure).

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.

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TABLE 5 Cylinder/Packing Oil Requirements for Various Gas Stream Componentsa, c, e

Gas Stream Cylinder Discharge Pressures, psig (barg)


Pipeline 0 - 1250 (0 - 86) 1250 - 2000 (86 - 138) 2000 - 3500 (138 - 241) b 3500 - 5000 (241 - 345) b Above 5000 (345) b
Quality
Natural Gas SAE 40 wt. Engine Oil R & O Oil (ISO 220)1.25 x Base Cylinder Oil (ISO 220) Cylinder Oil (ISO 320) Cylinder Oil (ISO 460)
Including R & O Oil (ISO 150) Rate w/Compounding w/Compounding w/Compounding
CNG (Dry) Synthetic Ester (ISO 150) 1.50 x Base Rate 2.00 x Base Rate 3.00 x Base Rate
Synthetic PAO (ISO 100)
Synthetic PAG (ISO 100) Synthetic PAO (ISO 150) Synthetic PAO (ISO 220) Synthetic PAO (ISO 320) Synthetic PAO (ISO 460)
1.00 x Base Rate 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 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

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Gas Stream Cylinder Discharge Pressures, psig (barg)
Nitrogen 0 - 1250 (0 - 86) 1250 - 2000 (86 - 138) 2000 - 3500 (138 - 241) b 3500 - 5000 (241 - 345) b Above 5000 (345) b

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

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Gas Stream Cylinder Discharge Pressures, psig (barg)
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 220) Cylinder Oil (ISO 460) Cylinder Oil (ISO 680) Synthetic PAG (ISO 100)
and H2 S > 2% to w/Compounding w/Compounding w/Compounding w/Compounding 2.00 x Base Rate
40%) 1.25 x Base Rate 1.50 x Base Rate 2.00 x Base Rate 3.00 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

a. See TABLE 6 for base rates.


b. Also requires water-cooled packing (except cylinders on JG:A:M:P:N:Q).
c. Engine oils suspend water from wet gas streams and form emulsions (gel/foam). Emulsions interfere with cylinder/packing lubrication and create deposits in system piping. R & O oil, cylinder oil, and
synthetic lubricants better tolerate wet conditions and prevent emulsion formation.
d. Verify oil pour point temperature is below gas stream temperatures to avoid oil solidification in low temperature regions.
e. Synthetic PAG lubricants cannot be contaminated with engine oil, R & O oil, cylinder oil, or synthetic PAO lubricants. Consult oil provider for compatibility limitations for fluids and materials that will be
exposed to PAG. Refer to Ariel flushing procedure in ER-96.5.11 when changing between incompatible fluids.

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Special Lubricant Certification - Lubricant suppliers offer special lubricant formulations for specific applic-
ations. Suppliers who certify formulation suitability for site conditions should provide appropriate doc-
umentation. Contact Ariel to verify warranty coverage.
NOTE: These lubrication recommendations TABLE 6 Cylinder/Packing Lube Oil Base Rate, Pint-
are general guidelines. Contact lubricant sup- s/Day/Inch (Liters/Day/mm) of Bore Diameter
plier for specific lubricant that meets TABLE 5
Frame Model Base Rate
guidelines.
JG:A:I:M:P:N:Q:R:S:W, KB100 0.3 (0.0056)
l Appropriate gas conditioning to remove liquids
and debris is required for effective cylinder and JGH:E:J:ACF 0.4 (0.0074)
packing lubrication.
JGK:T:C:D:F:Z:U:B:V, KBK:T:Z:U:B:V 0.5 (0.0093)
l If lubrication appears inadequate, the lubricant
and flow rate will need reviewed.
Rate Calculation Notes
Packing Lube Rate - Double piston rod diameter and treat it like a cylinder to calculate packing lube rate.
For cylinders with a tail rod, calculate lube rate for each of the two packings separately and add both values
toward the recommended total daily lube rate.
Lube Points - Cylinders for JG:A:M:P:N:Q:R:H:E:J and KB100 frames with bore diameters less than 13"
(<330 mm) have one point bore lube as standard; top and bottom bore lube is available as an original pur-
chase option, (except for all Class T cylinders and 1-3/4JG-FS-HE class cylinders, which have standard
multi-point lube).Cylinders for all other frames use standard multiple bore lube points. Piston rod packings
for high-pressure cylinders use two-point lube. For multiple lube points, the required cylinder or packing lub-
ricant divides equally among the lube points.
Recommended Daily Lube Rate Calculation Example
JGJ/2, with Pipeline Quality Natural Gas (see TABLE 5), the following actual cylinder bore diameters as
shown on cylinder data plate, 1.5 inch (38.1 mm) diameter piston rod, with mineral oil lubricant:
13.00"J (330 mm) at 100 psi discharge pressure (6.89 bar). Factor = 1.
9.75"J-CE (248 mm) at 577 psi discharge pressure (39.8 bar), Crank End. Factor = 1.
5.125"J-HE (130 mm) at 1636 psi discharge pressure (112.8 bar), Head End. Factor = 1.25.
TABLE 7 Cylinder & Packing Lube Calculation, Pints Per Day (Liters Per Day)
Cylinder Bore Packing Sub-Total
1 x 13.00 in. x 0.4 ppd/in. = 5.2 2 x 1.5 in. x 0.4 ppd/in. = 1.2 6.4
1 x 9.75 in. x 0.4 ppd/in. = 3.9 2 x 1.5 in. x 0.4 ppd/in. = 1.2 5.1
1.25 x 5.125 in. x 0.4 ppd/in. = 2.6 N/A 2.6
Recommended Total, ppda = 14.1
1 x 330 mm x 0.0074 lpd/mm = 2.4 2 x 38.1 mm x 0.0074 lpd/mm = 0.56 (3.0)
1 x 248 mm x 0.0074 lpd/mm = 1.8 2 x 38.1 mm x 0.0074 lpd/mm = 0.56 (2.4)
1.25 x 130 mm x 0.0074 lpd/mm = 1.2 N/A (1.2)
Recommended Total, (lpd)b = (6.6)

a. ppd = pints per day.


b. lpd = liters per day

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,

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0.65 specific gravity, sweet gas and cylinder MAWP. If the applied speed is not specified, the cycle time is
based on maximum rated speed of the frame or cylinders, whichever is less. The lube sheets in the Ariel
Parts Book state gas conditions and list the base rate multiplier at each lube point.
Break-in Rate - Set the break-in lube rate about twice the recommended daily rate (150% minimum); i.e.
set the break-in cycle time about half the normal cycle time (67% max.) to increase lube rate. Maintain
break-in rate for 200 hours of operation for new equipment. Contact Ariel if existing pump is incapable of min-
imum flow rate required.
Lube Rate and Speed - Recommended lube rates for break-in or normal operation, in seconds per cycle,
are calculated at the frame rated speed (RPM) stamped on the frame data plate or the cylinder rated RPM
stamped on the cylinder data plate, whichever is lower. Lube rate decreases with speed, (as compressor
actual running speed decreases, cycle time increases, reducing lube rate):
(RPMmax ÷ RPMactual) x cycle time seconds from lube plate = cycle time seconds at actual running speed.
See the Ariel Parts Book Lubrication Sheets for the Cycle Time (seconds) vs. RPM (compressor speed)
table at various running speeds at stated gas operating conditions and lubricant.
Adjusting the cycle time changes the lubrication rate for all the compressor cylinders and packings supplied
by a particular pump. To change the lubrication rate for only one cylinder or packing requires individual
divider valve changes. Contact your packager or Ariel for information.
To set proper force-feed lubricator pump flow rate, read or measure the cycle time from the installed device.
For a magnetic cycle indicator assembly, time the cycle from initial indicator pin movement at the fully retrac-
ted position to the time when the pin returns to the fully retracted position and just begins initial movement
out again. Adjust the lubricator pump to provide the required cycle time.
NOTE: Pump output can become inconsistent if flow rate is set too low.
Changes in operating conditions (such as gas properties or pressures, temperatures, flow requirements, or
cylinder re-configuration) require lubrication rate re-calculation and possible force-feed lubrication system
alteration. Consult TABLE 5, the Packager, and/or Ariel.

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.

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Force Feed Lubricator Adjustment
Verify the force feed lubricator is set at the break-in rate shown on the force feed lubricator data plate (see
ER-96.0.1). To adjust, loosen locknut and turn the pump plunger stroke adjustment screw until the indicator
strokes at the proper rate, then tighten locknut.

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:

l Viscosity Index l Anti-Wear Protection


l Oxidation and Rust Inhibition l Extreme Pressure Protection
l Pour Point l Friction Characteristics
l Detergency l "Washing" Resistance

Petroleum-Based Lubricants (Mineral Oils)


Paraffinic Oils Napthenic Oils
l Most common mineral oil base stock l Better additive solvency
l West Texas Intermediate or Arab Light l South Louisiana crude
l Solvent refined or hydro-treated l Solvent refined or hydro-treated
l Higher wax content l Lower wax content
l Viscosity Index greater than 90 l Viscosity Index less than 80
l Pour point around 25°F (-4°C) l Lower Pour Point than paraffinic oils

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.

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Polyalphaolefins (PAO) - Synthesized Hydrocarbons
l Compatible with mineral oils l Soluble in hydrocarbon gases
l Most of the same properties as mineral oils l Low Pour Point
l Requires additives to improve detergent action l High Viscosity Index of about 150
and improve seal compatibility
l High Flash Point
Organic Esters - Diesters and Polyolesters
l Compatible with mineral oils, PAO & PAG oils l Primarily used in air compressors
l Incompatible with some rubbers (o-rings), l Leaves a soft carbon deposit when oxidized
plastics, and paints; compatible with Viton
l Breaks down in water
l Higher Viscosity achieved with additives or
blending with heavier oils l Higher Flash Point than mineral oils

l Low Viscosity of about 85-90 cSt at 40°C l Low Viscosity Index of about 70

Polyalkylene Glycols (PAG)


l Very good for high pressure applications
l Does not foul reservoirs. Excellent for reinjection applications.
l Resistant to hydrocarbon gas dilution.
l Most are water soluble, verify application with lubricant supplier
l Not compatible with mineral or PAO oils, some plastics and paints
l Requires complete system flush when changing to or from mineral or PAO oils
l Compatible with Viton and HNBR
l Poor inherent oxidation stability and corrosion protection - requires additives
l Not recommended for air compressors
l Very high Viscosity Index greater than 200

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.

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Compounded Cylinder Oils
Compounded oils are formulated for steam and/or compressor cylinders. They enhance oil film strength to
counter the effects of water, wet gases, solvents, etc. present in gas.
Additives contain an animal, vegetable fat, or synthetic base. Animal and vegetable based additives yield
low oxidation resistance and poor performance at high temperatures. However, most compounded oils
today use synthetic instead of natural additives.
NOTE: Do not use compounded oil in a compressor frame; the additives are incompatible with
lead based bearing materials.

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.

Used Engine Oil


Used engine oil supplied for cylinders and packing lubrication must meet requirements for cylinder and pack-
ing lubrication and be appropriately filtered (ß5=10 and ß12=75 with an ISO 4406 cleanliness code of
17:16:14 ). Monitor oil viscosity to verify adequate quality.

Liquids in Gas
Higher viscosity lubricants or specially compounded lubricants can compensate somewhat for liquids in the
gas stream.

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For the most effective cylinder and packing lubrication, remove liquids from gas before it enters
the compressor. These lubrication recommendations are general guidelines. If recommended
lubricants or flow rates appear inadequate, review both. Contact lubricant supplier for specific
lubricant recommendations.

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.

DATE: VER: ECN: DESCRIPTION:


06-10-2019 32 201900635 Revision number incremented to accommodate Spanish word choice changes.

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