Evaluating A Rotary Screw Lubricant Before You Buy

A Product Data Sheet Primer

Years ago, a New York area clothier ran a TV ad proclaiming; An educated consumer is our best customer. I loved that ad. From a marketing standpoint it was new, fresh, and pro-consumer. It basically said, you dont have to pay top-dollar for quality merchandise. When you consider the total operating costs (maintenance, replacement parts, associated productivity, etc), that are generated either by purchasing and utilizing the wrong lubricant and/or inferior product in rotary screw compressors, you realize that it doesnt pay to buy cheap or let some slick salesman sell you on, ours is the best lubricant you can use in your compressor! Or conversely, you dont need that expensive synthetic stuff just to run your compressor! But expensive doesnt necessarily mean superior either. My grandfather once told me, Son, were too poor to buy cheap. Which basically meant, if you cant afford a good quality material that will last a long time dont buy anything at all. That is why Im writing this paper. A lubricants product data sheet can tell you a hell of a lot or nothing at all! Be smart, ask questions. If the data isnt there or appears to be misleading, ask questions. Process air is probably the most important utility in a manufacturing/service facility. Its not too hard to achieve long service life with any compressor if its maintained properly. Good compressor maintenance starts with using a good quality lubricant. My goal is two-fold; First, Id like to outline what tests should be included on a product data sheet for an air compressor lubricant, secondly, Id like to define each of these tests and associate them to what primary function they effect in regard to performance in a rotary screw compressor. Ill also present to you some additional screening tests that pertain to this application. The KISS method is used throughout this paper. The KISS method, if you dont already know, stands for, keep it simple-son. That works for me, hopefully it will work for you too!! PRIMARY TESTSViscosity- measured by ASTM D-445. Two (2) viscosity measurements should be on the product data sheet, a 40deg.C and 100degC measurement. The forty (40) -degree viscosities indicate what ISO grade the lubricant is (more on this later). These viscosities will be reported in centistokes, (cSt). Also known as the kinematic viscosity further defined as the time required for a fixed amount of oil to flow through a capillary tube under the force of gravity. Historically, it was quite common to see additional viscosity data in SUS. SUS defined as Saybolt Universal Seconds (ASTM D 88), was another means of interpreting viscosity. The Saybolt Company invented the viscometer, which is the devise that measured the flow of a lubricant, hence the name. Compressor company (OEM) engineers specify the viscosity grade or ISO grade by calculating the bearing life under normal operating conditions. The diameter of the rotor journal, speed of rotors, and operating temperature all are factored in. Typically, most rotary-screw applications call for an ISO-46 fluid. ISO grade- In 1975 the International Organization for Standards (ISO) issued International Standard ISO 3448 providing a classification system for liquid lubricants according to viscosity. This standard covers the entire range of lubricants in normal industrial applications. As stated earlier, most rotary-screw applications call for an ISO grade 46 fluid. Viscosity Index VI- Measured by ASTM D-2270- the viscosity index indicates the rate of change in viscosity of an oil within a given temperature range. Simply put, if oil has a high VI (usually > 120) the oils viscosity will show less change with difference in temperature as compared to a low VI (usually <110) product. Knowing the VI comes in handy if your application sees wide temperature variations. For instance, if your compressor runs on an ISO 46 lube, and your ambient can go down below 0C/32F, you should strongly consider using a high VI product. A higher actual viscosity will put more load (starting torque) on the electric motor that drives your compressor. This situation will cause a higher draw of amps upon start-up, which in turn shortens the life of the drive motor. A higher VI product would allow you to draw less amperage at lower ambient temperatures. In addition, if your VI is too low, less lubricant will reach vital areas that require lubrication upon start-up (rotor bearings). Flash and Fire Points- Measured by ASTM D-92 (Cleveland Open Cup Test), the flash point of oil is the lowest temperature at which it gives off sufficient vapors that will ignite when a small flame is periodically passed over the surface of oil. The fire point is the lowest temperature at which oil ignites and continues to burn for at least 5 seconds. These tests are run to aid in the generation of MSDS sheets and help plant supervisors implement the appropriate safety measures against potential fire hazards. SAFETY FIRST. Compressors generate heat from the compression cycle. A portion of this heat is passed on with the discharge air. Flash fires and explosions have happened due to a combination of hot turbulent air and oxides of metals (i.e., iron). Though this situation was more common in reciprocating applications utilizing mineral oil-based products, it can also happen in rotary air applications. Synthetic-based products generally have much higher flash and fire points as compared to mineral oil-based products and are gaining more and more acceptance for this very reason. BE CAREFUL! Auto ignition temperature-Measured by ASTM D-2155 or E659, Another SAFETY FIRST TEST! This method determines the temperature at which air oxidation leads to ignition. Pour Point- Measured by ASTM D-97, the pour point is the lowest temperature at which oil will pour or flow under prescribed conditions when it is chilled without disturbance at a fixed rate. This test along with the VI, indicates the performance characteristics at lower operating temperatures. Electric drive motors and overall lubrication is vital at low ambients. If oil cannot flow, it will not lubricate properly. Water Separability- Measured by ASTM D-1401, This test method measures the ability of the lubricant to separate from water. Per the ASTM test method, this test is only to be used as a guide for determining the water separation characteristics of oils subject to water contamination and turbulence. It can be used to evaluate both new and in-service oils. Basically

40milliliters of water and 40 millilitres of oil are placed in a graduate cylinder and heated to a determined temperature. Once the temperature has been achieved a stirrer is introduced into the mixture and agitated at 1500rpm for five (5) minutes. The mixture is than inspected every 5 minutes to evaluate the volume of oil, water, and emulsion. The amount of time taken to achieve a split is also recorded. The test is usually terminated by 60 minutes if separation has not occurred. The data for this test should be reported in the following manner; i.e., 40-40-0 (20). The sequence of numbers represents millilitres of oil, water, and emulsion respectively. This test basically indicates how the lubricant will perform in the compressor oil/water separator. This is very important especially in high humidity conditions. A word of caution here, oil/water separators vary in type and design construction not only from model to model but also from supplier to supplier. In addition, mechanical parameters (i.e., drain lines, lubricant velocity) play an important role towards efficiency of oil/water separation. Good demulsibility is a VERY important characteristic towards the successful lubrication of any rotary compressor. So any rating less than 40-40-0 (15) may not be up to snuff. Specific Gravity-Measured by ASTM D-287 (hydrometer) or 1480 (Pycnometer), this test is defined as the weight in air of a given volume of material at a stated temperature to weight in air of an equal volume of distilled water at the same temperature. The test (D-287) is run by pouring the test lubricant into a hydrometer jar, removing all air bubbles, than placing a hydrometer into the fluid. The gravity is than read off the hydrometers scale and corrected for temperature. In the ASTM D1480 test, a lubricant sample is introduced into the pyncnometer, equilibrated to the desired temperature, and weighed. The density or specific gravity is then calculated from this weight and the previously determined calibration factor, and a correction is applied for the buoyancy of air. Generally, the gravity of oil was needed for bulk storage purposes, selling price (sold by volume), and transportation (weight) issues. However, one could help determine the species of a lubricant basestock by the gravity. Petroleum-based products gravity range is usually from .8200 to .8500. Synthetic base stocks generally are greater than .8700 with complex esters and glycol-based products as high as .9950. Rust Prevention Measured by ASTM D-665A & B, this test indicates the ability of lubricating oil to prevent corrosion during the lubrication of ferrous parts in the presence of water (A), and synthetic seawater (B). Normally, part A data from this test is good enough to spec out a rotary compressor fluid. But if you have any long term storage issues or plan on sending your compressor overseas in the hull of a cargo ship you should consider part B data also. Remember, compressors make a lot of water, most lubricants will saturate up to approximately 2000ppm water in typical conditions. If your additive package isnt up to snuff, youll have a lot of orange color debris (rust) floating around, which can cause havoc in a rotary compressor, (plugged sep filter, shorten life of rotor bearings, pit the rotors, etc.). 4-Ball Wear Test- Measured by ASTM D-2266, this test measures the loss of weight and dimension on surfaces subjected to friction. In the test, 4 balls are arranged in the form of an equilateral tetrahedron. The three lower steel balls are clamped in placed and submerged in the test fluid. The fourth ball, which is rotating at 1200 rpm, is placed in the center of the lower 3 balls with 40kg of applied pressure. The running temperature is usually set at 75 degC. The test duration is one (1) hour. During this test circular scars are worn in at the contact surfaces of the 4-balls. These diameters are than measured under a microscope and are reported as millimeters scar. A Four-ball rating of less than 8 is desirable for most rotary screw applications. Generally, this test indicates the lubricants performance in regard to friction reduction at the bearings of the rotor(s). Foaming Characteristics-Measured by ASTM D-892, This test covers the determination of the foaming characteristics of lubricating oils at specified temperatures, which is accomplished in three (3) sequences, and a good quality rotary screw lubricant should have excellent results in all three. In all three sequences, a specified amount of oil is maintained at the required temperature and is blown with air at a constant rate for five (5) minutes, then allowed to settle for ten (10) minutes. The volume of foam generated is measured at the end of both periods. Rotary screw mechanical components have the potential to generate large amounts of foam if the lubricant used is not appropriately additized or synergistically balanced to prevent foam generation. The rotors and separator filter are the main culprits here. Simply, the rotors and sep. filter act as a mix-master blender and homogenizer all in one. Add in the velocity, temperature, and pressure of the lubricant along with any extraneous contaminants that will chemically cause foam and you have the potential for one huge foam bath!! Normally, the foam is seen in the site glass of the sep. filter. Foam causes loss of lubrication and will eventually result in mechanical failure. Air-ends are expensive, so any lubricant with foam rating higher than nil should not be used in a rotary screw application. Copper Strip Corrosion- Measured by ASTM D-130, this test measures the lubricants corrosiveness to copper and copper alloys. In the test, a polished copper strip is placed in a stainless steel bomb containing the test fluid, sealed, and submerged into a test bath maintained at 100degC for three (3) hours. The strip is than wiped of residual oil and matched against the ASTM tarnish/corrosion std. A rating of 1a-1b is most desirable, a lubricant with a rating of 2a or higher in this temperature/time frame should be avoided. Even though we are in the age of plastic, there is still plenty of copper and/or copper alloy materials found throughout a compressor,(i.e., return lines temperature solenoid valves). Sulfur containing lubricants, (EP gear variety), should never be introduced into a rotary screw compressor. Not only do they attack copper but also build acids in a rotary screw type environment, which will certainly shorten the life of your lubricant. Conradson Carbon-Measured by ASTM D-189, this test measures the amount of carbon residue remaining in an oil after the oil has been subjected to extreme heating in the absence of air. In the test, a sample is weighed into a crucible, covered, then placed into an oven and burned at an elevated temperature. The remaining carbon residue is then weighed and expressed in %wt. Well, I know what your thinking. Your thinking, a rotary screw compressor introduces air into the lubricant at elevated temperatures, so what gives here? Allow me to explain- You usually find this test on the product data sheets for reciprocatingair lubricants, ISO grades 100 and 150. It is chiefly used in that area to help predict the cleanliness of the exhaust valves while in service. In general, once oil oxidizes, its nice to know approximately how much carbon will be produced from the fluid. So if you narrowed your lubricant search down to two (2) different lubes from two different suppliers and the make or break deciding issue comes down to the Conradson carbon values, pick the lube with the lower Conradson carbon value. Alchor High Temperature Deposition Test- This test was originally designed to evaluate turbine oils thermo/oxidative performance characteristics at elevated heat regimes. Alchor is the name of the company who invented the test rig. Well, rotary screw compressors circulate lubricant also at elevated temperatures. This test has tremendous value for screening lubricants that are being considered for use in rotary-screw applications. In the test, oil is circulated through a sump pan (cabinet) at a constant temperature (usually 200deg. F). It is then pumped and passed over a metal tube, which is kept at a higher temperature (usually 450deg. F). Air is passed through this cabinet and over the rod at a rate of 1000cc/min. The test

duration is 48 hours. The oils viscosity and total acid number changes are then calculated. In addition, the tube that the lubricant flowed over is evaluated for deposits. Youll probably never find any Alchor deposition test data on any rotary screw lubricant product data sheet. But, if youre a stickler for detailed data, call up the lubricant companys technical service department and ask them if they have this data available, if they dont you may want to consider looking elsewhere for a rotary screw lubricant. Rotary bomb oxidation- Measured by ASTM D-2272, Usually listed as RBOT, this test utilizes an oxygen-pressured bomb to evaluate the oxidation stability of new oils. The measured amount of oil, water, and copper catalyst coil are placed in a glass bomb container equipped with pressure gage. The bomb is charged with oxygen then placed in a constant-temperature oil bath and rotated axially at 100rpm. The number of minutes required to reach a specific drop in gage pressure is the oxidation stability of the test sample and is reported in minutes. A word of caution here. Some synthetic basestocks (PAOS) perform better than others, (diesters/polyolesters), regarding this test and should not be solely used as a critical factor in deciding on whether to use an ester or PAO-based product. Some compressor OEMs utilize a combination of PAO/ester technology to best capture the positive characteristics of both. Hydrolytic stability-Measured by ASTM D-2619, Other names for this test are, Coke bottle test or beverage bottle test hydrolytic stability test for good reason. A weighed sample of fluid, specific amount of water, and a copper test specimen are sealed in a pressure-type (glass) beverage bottle-hence the name. The bottle is rotated, end over end, for 48 hours in an oven at 93deg C (200deg F). The weight change of copper is measured along with the viscosity and acid number changes of the test fluid. In addition, the acidity of the water layer is determined. Though this test is a regular for hydraulic oils, it could also be used for screening any circulating fluid.

For more information regarding compressor lubricants, please contact; Darren J. Lesinski Technical Service Manager/Industrial Fluids Royal Lubricants and The ANDEROL Co. (973) 887-7410, X221 e-mail: dlesinsk@royallube.com