5 Tips for Optimizing Screw Compressor Performance with the Right Oil
Screw compressors are straightforwardly designed rotary positive displacement machines that can operate at high speeds across a broad range of operating pressures and the flow rates. They are also portable and dependable. Since screw compressors are reliable and efficient, they are essential in many industrial applications. The screw compressor is one of the most often used varieties of oil-lubricated compressors. The most common kind of compressor in use is the positive displacement variety. A female and a male rotor make up the major components of the screw compression element. The rotors move toward each other when the volume between them and the housing reduces. The dimensions of a screw, including its length, profile, and discharge port shape, determine its pressure ratio.
Tip 1: Choose the Correct Oil Type
Screw compressors use large amounts of oil in the rotor housing. During the compression phase, the oil mixes with the air; after that, it is removed. There are a few options when it comes to selecting the proper oil for your screw compressor:
- Understanding Different Oil Types
Mineral Oil: Mineral oil is more economical for daily operations because it is typically less expensive than synthetic oil. It offers sufficient lubrication and protection for most typical operating situations. On the other hand, standard oil may not function as well in extremely hot or cold conditions or under high loads and, therefore, requires more regular oil changes than synthetic oil. Standard Oil might be an intelligent choice if operational expenses are a significant concern.
Synthetic Oil: Synthetic oil provides better protection and lubrication over a more extensive temperature range. It can lessen wear and increase equipment longevity, particularly for screw compressors. It can withstand oxidation better, meaning oil changes should happen more frequently. Additionally, synthetic oil may lower energy usage and increase compressor efficiency. Though it is typically more costly than mineral oil, its advantages may exceed the expenses in some circumstances. It’s also a wise option for lower wear and longer maintenance intervals.
Semi-Synthetic Oil: Screw and reciprocating compressors are intended to use Semi-Synthetic Oil partial-synthetic blend lubricant. Semi-Synthetic Screw Compressor Oil provides:
- Oxidative solid and thermal stability.
- Resistance to carbon and varnish formation.
- An innovative additive system.
Even under somewhat harsh operating circumstances, Semi-Synthetic Screw Compressor Oil provides exceptional performance. A synthetic and mineral oil combination that balances price and performance.
- Matching Oil Type to Compressor Requirements
Consult your compressor’s working conditions and specifications to determine the appropriate type of oil. Examine your screw compressor’s warranty and handbook before choosing a lubricant. Use the oil that the manufacturer advises explicitly for the kind of screw compressor you are using. Take into account variables like temperature, pressure, and workload. Make sure the lubricant stock you use is suitable for your screw compressor and the operating environment.
Tip 2: Monitor and Maintain Proper Oil Levels
- Importance of Correct Oil Levels
It’s vital to keep your screw compressor’s oil level at the proper level. Excessive oil content might result in foaming and high pressure, which could cause harm. If you add too much oil, the air compressor may “spill” oil or come out of the compressor pipes. Overflowing air oil separators and inline filters in the compressed air supply can harm pneumatic tools and equipment.
- Regular Oil Level Checks
Once your compressor is running, check the oil level using the sight glass. To extend the usable life of oil and eliminate materials such as calcium and metal filings, replacing oil filters every 2,000 hours of operation is recommended. Reduce the time between oil changes and samples when there are demanding circumstances, like high temperatures or dust and debris in the intake air. Additionally, if you’re using food-grade oil, follow the analyst’s report’s recommendations and sample your oil every 1,000 hours. Naturally, oil-free screw compressors don’t require as many oil changes as oil-lubricated ones do, which lowers the initial cost of air compressor maintenance.
Tip 3: Change Oil Regularly
- Oil Change Frequency
Keeping your compressor operating at peak efficiency requires routine oil changes. For lubricated and oil-flooded screw compressors to remain in optimal operating condition, frequent oil changes are needed. You should include this in your routine preventive maintenance (PM) services. Mineral oils and mixtures need to be changed approximately every 4,000 operation hours. Up to twice as long may pass between synthetic oils. You must change the oil every six to twelve months, even if the service hours still need to be completed. If your screw compressor is operating in highly unclean conditions, oil changes may be necessary more frequently.
- Signs It’s Time for an Oil Change
You must replace the oil at least once a year, regardless of operational circumstances or working hours. This is because the oil will eventually deteriorate and stop providing enough lubrication. Most of the time, more frequent oil changes are required. Flush out polluted or unclean oil and replace it with brand-new oil. Here are several indicators that it’s time to replace your oil:
- Thick or opaque oil
- Discoloration
- Visible granular particles
- Odorous smell
Tip 4: Use High-Quality Oil Filters
- Role of Oil Filters in Performance
Oil filters are responsible for removing any condensate, dirt, sand, or rust particles that may be present in the oil. This safeguards the internal components of your compressor, like the bearings and the oil separator, from being damaged. Maintaining clean oil optimizes performance and lessens the amount of wear on interior components. It is the responsibility of an oil filter to remove contaminants from oil that can cause damage to other components of the air compressor. An oil filter comprises a paper filter element that is folded like a harmonica.
- Choosing the Right Filter
Selecting a non-authentic oil filter means sacrificing certain features to fit more than one screw compressor. Generic or non-genuine oil filters are not manufactured and tested precisely for a particular compressor. Neglecting to replace the filter can cause significant harm to your downstream products, air accessories, and compressed air system. This leads to decreased efficiency, increased expenses, and malfunction risk. Equipment corrosion following the filter can result from failing to replace the filter element.
Tip 5: Conduct Regular Oil Analysis
- Benefits of Oil Analysis
By examining the contents of the lubricant, you may quickly and safely assess the condition of your screw compressor with an oil study. Oil is an ideal sample for evaluation because it is used for cooling and lubricating. You can ascertain the level of contamination, the rate of wear, and the general state of the machine by examining a sample of used machine oil. The main advantage of an oil analysis is that it serves as an early warning system, letting you know about possible issues before the compressor fails or shuts down.
- How to Perform Oil Analysis
Taking an oil sample from an industrial screw compressor is not too difficult. You have two options: hire a service provider, or do it yourself. The procedures for extracting an oil sample from a compressor are as follows:
Safety First: Before starting, always make sure you’re wearing the proper protective gear.
Select the Appropriate Oil Sampling Kit: Before taking oil samples, an oil sampling kit is required. These kits usually include tubing, other instruments needed, and a sample vial. To avoid contamination, the sample bottle needs to be dry and clean.
Take a Sample: Once the area has been cleaned, you can begin gathering the oil. Your sampling kit will determine the precise procedure. The sampling tube should normally be connected to the sample point and then to your sample bottle.
Label and Seal the Sample: After obtaining the sample, firmly close the container and attach the label.
Submit the Sample for Analysis: Lastly, submit the sample to a lab for examination. They will examine the oil to look for wear particles, pollution, and other clues about the condition of your air compressor.
An oil analysis report lists all the elements, pollutants, and additives. A lab will produce a report that rates the risks as usual, monitors them, and indicates whether they are abnormal or critical. Remember that a compressor lubricant’s ability to remove heat from the air end is one of its most essential functions. Compressing the air produces a great deal of heat. If this heat is not dissipated, the gears, seals, and bearings will inevitably fail quickly.
Conclusion
Using the appropriate oil can optimize the performance of a screw compressor. It can be accomplished by selecting the proper oil type, ensuring that the oil levels are maintained appropriately, changing the oil regularly, utilizing high-quality oil filters, and doing oil analysis regularly. You may extend the life of your compressor, save downtime, and increase its efficacy by implementing these recommendations. To guarantee that your screw compressor functions at its peak performance, put these principles into action.