The Basics of Rotary Screw

Compressor Lubricants

Wayne Perry, Senior Technical Director

Kaeser Compressors, Inc.
 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

Lubricant is a critical component in rotary screw com-

pressors. Understanding the characteristics of lubri-
cant types helps ensure their proper application and
increases customer satisfaction by extending the ser-
vice life of compressors. Below we discuss the types
of lubricants and then discuss factors that reduce the
effectiveness of lubricants and cause premature wear
or damage in rotary screw compressors.

Types
There are seven basic types of lubricants used
in compressors today. Each type of lubricant
has advantages and disadvantages for specific
applications.
These are:
1. Mineral oils
2. Synthetic hydrocarbons
3. Organic esters
4. Phosphate esters
FIGURE 1: there are seven basic types of
5. Polyglycols
lubricants used in compressors today.
6. Silicones
7. Blends (Semi-synthetics)

Mineral Oils Synthetic Hydrocarbons

Mineral oils (petroleum oils) have long been used Synthetic hydrocarbon lubricants are engineered
in various types of compressors. Their use in rotary for particular applications. For compressor
screw compressors was common until the 1980’s. applications, polyalphaolefin (PAO) base stock is
Some manufacturers’ factory filled with motor oil and most commonly used. PAOs provide many of the
some used automatic transmission fluid. Mineral best lubricating features of a mineral oil without the
oils began to lose favor when oil recyclers began to drawbacks. Although PAO components are derived
charge for oil disposal. With oil change intervals as from petroleum base stock, they are chemically
low as every 1000 hours, many manufacturing plants re-engineered to have a consistent, controlled
had to change eight times per year. molecular structure of fully saturated hydrogen and
An advantage of frequent oil changes is that carbon.
contaminants in the compressor are removed with Because their molecular structure is homogeneous,
the waste oil. In highly contaminated environments, their properties and characteristics are predictable.
mineral oil is still used for this reason. Mineral oils PAOs separate from water extremely well, are
have the disadvantage of a complex mix of natural chemically stable and have low toxicity. PAOs,
hydrocarbon molecules. There are waxes that however, are not good solvents. The additive
solidify at low temperatures, volatile components chemistry must be adjusted for that fact. Additive
that vaporize and natural mineral oils tend to oxidize packages in PAO lubricants are usually blended to
quickly, forming varnish and sludge, when exposed beyond their saturation point at cool temperatures.
to high temperatures and elevated pressures. Under the normal operating conditions of

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 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

compressors, this is not a problem. The elevated react with water to form corrosive acids and volatile
temperature and constant motion keep the additives alcohols.
dissolved. Diesters are not commonly used in rotary screw
When PAO lubricants are stored for prolonged peri- compressors today, but still enjoy wide popularity
ods of time, it is possible for some of the additives to among large reciprocating compressor users where
condense and cause the lubricant to have pockets of the diesters’ solvency and resistance to carbon
cloudiness in the storage container. These additives formation is a plus for extended valve life. Polyol
will return to solution with a bit of agitation/stirring. esters have similar characteristics to diesters but
In a paper presented to an engineering meeting in have the added advantage of being stable at higher
Sweden several years ago, a major bearing manu- temperatures and oxygen concentrations. Although
facturer shared results of their testing of lubricants for the primary market for polyol esters has been for use
use in rotary screw compressors. Their conclusion in turbines, these fluids are being used in some high-
was that PAO lubricants were the best lubricants for pressure rotary screw applications.
rolling element bearings used in screw compressors.
Phosphate Esters
Pure PAO fluids have a tendency to cause certain
low nitrile Buna-N elastomers and some other Phosphate esters have very limited application.
synthetic materials to become brittle and crack. For Phosphate esters have a poor viscosity index,
compressor applications, a small amount of ester poor tolerance of heat and moisture, and become
fluid is usually blended in the mix to counter this corrosive as they degrade. For that reason, service
tendency. The ester also helps keep additives in life is very limited and fluid changes are required
solution. often. They can, however, be made fire resistant,
and once ignited, they will only continue to burn if the
Organic Esters source of ignition remains present. Petro-chemical
The next class of synthetics is the organic esters. plants, refineries and other high-risk facilities form
The two primary types used in compressors are the primary market for this type of lubricant.
dibasic acid and polyol. Dibasic acid lubricants are
Polyglycols
better known as diesters. Diesters were the most
popular synthetic lubricants when synthetic lubricants Polyglycol fluids, sometimes called PAG fluids (poly-
first became common in compressor applications alkylene glycol), were first developed for natural
in the 1970’s and 1980’s. They have a number of gas compressors. They can be manufactured from
desirable qualities for compressor applications. They either of two primary chemical stocks, or a blend of
have a stable viscosity over a wide temperature these stocks. Propylene oxide has the characteristic
range, high film strength, good metal wetting of being hydrocarbon soluble and water insoluble.
characteristics and a low vapor pressure at high Ethylene oxide has opposite characteristics, being
temperatures. water-soluble and hydrocarbon insoluble. With a gas
analysis, blenders can adjust the amount of each
Diesters are strong solvents. As such, they readily
type to produce a final product with the correct char-
accept additives, making them customizable for
acteristics required by an individual application. The
particular applications. Being a strong solvent,
solubility differences in the two basic fluids make the
however, is also one of their primary drawbacks.
chemistry of the additive package very important. For
Diesters will dissolve paint and varnish, cause certain
natural gas applications, the fluids are blended so
common elastomers to swell and deteriorate and can
they are not diluted by the particular hydrocarbon gas
damage some common downstream components
being compressed.
of compressed air distribution systems. Esters can

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 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

Polyglycol fluids for use in air compressors are

Causes of bearing damage in rotary
compromise fluids. They were developed to reduce
complaints about poor lubricant life and varnish screw compressors
deposits. The formation of varnish is an indication of
a petroleum or synthetic hydrocarbon lubricant that
Water
has failed. Since polyglycols do not form varnish, The most common and most damaging contaminant
there is no visual indication that the lubricant has in rotary screw compressors and rotary screw
failed. Polyglycols attract water and mix readily. This vacuum pumps is water. The primary source of
characteristic makes separation from condensate water contamination in rotary screw compressors is
difficult and reduces their ability to protect bearings. the inlet air. Ambient humidity and the compressors
The saturation point for these lubricants is much operating conditions affect water formation in the
higher than for mineral or synthetic hydrocarbon lubricant circuit. A major bearing manufacturer has
fluids, but water entrained in the fluid beyond this stated, “It is well known that free water in lubricating
point will separate into free water. oil decreases the life of rolling element bearings
by ten to more than one hundred times…”. When
Silicones bearing life calculations are made, the assumption
Silicone fluids have been available for many years. is that the lubricant contains 65 to 100 ppm of
They have excellent resistance to heat, oxidation water. This is a normal amount of water that can be
and vaporization. Being chemically inert, they expected to be present in new PAO lubricant. An
can be used in applications where exposure to increase to 300 ppm will result in an actual bearing
oxidizing agents is possible. High cost, leakage, life of about half the calculated life. Water content
and poor lubricating properties limit their proper of 1000 ppm or more is not uncommon in operating
use to applications requiring their unique chemical compressors.
characteristics. Further, there are many applications Water can be present in a compressors’ lubricant
that require a silicone-free system, painting is one circuit in both a dissolved state and a free state.
example, and silicone lubricants should be avoided. Lubricants, like air, have a saturation point.
Depending on the type of lubricant, a certain amount
Blends (Semi-Synthetics) of water will be dissolved in the fluid. Once the
Virtually all synthetic fluids, except silicones, lubricant reaches its saturation point, additional
are actually blends of base stocks and additives water will condense to form free water. The extreme
engineered to provide the desired characteristics. examples are pure PAO base stocks that have
When a fluid is referred to as a semi-synthetic, it non-polar molecules and polyglycol lubricants that
is usually a blend of a synthetic stock, usually a have highly polarized molecules. PAO lubricants are
PAO, and most likely a Group I or Group II mineral sometimes described as being hydrophobic because
oil. The goal of most blends is to provide many of they do not easily combine with water, reaching their
the benefits of a pure synthetic at a lower cost. A room temperature saturation point at just over 100
good application for a blended fluid is one where ppm.
contamination in the ambient air necessitates more PAO lubricants separate from water readily so
frequent lubricant changes. the free water can be easily drained from the
Note: Food grade lubricants are usually either compressor. Polyglycol lubricants, on the other hand,
PAO-based or tech white mineral oil based with are sometimes described as hygroscopic. They
a very limited additive package. This limited combine readily with water and can be found with
additive package results in a significantly as much as one percent of their volume as water
reduced service life when compared to non-food molecules (10,000 ppm).
grade versions of the same lubricant.

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 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

Rolling element bearings, like those used in rotary fractures. This will continue until small flakes of the
screw compressors, rely on elastohydrodynamic bearing surface begin to break away. This debris
lubrication. That means that the elements ride moving through the bearing will cause additional
on a film of lubricant as they roll across the race. damage and lead to the failure of the bearing.
Lubricants are formulated to have sufficient film When standard petroleum oils were used in rotary
strength to prevent contact between the elements screw compressors, the accumulated water was
and the race. The viscosity of lubricants increases removed when the oil was changed about every six
as pressure increases. Under the extreme conditions weeks (1000 hours). With extended life synthetic
found in bearing lubrication, the lubricant can lubricants, water may accumulate for 8000 hours
momentarily become a solid. Water, however, does if it is not drained from the separator reservoir
not increase in viscosity as pressure increases. periodically. Without regular monitoring, significant
Dissolved water can weaken the film strength of amounts of water can collect in the lubrication circuit
some lubricants and free water has no effective film and reduced bearing life can be expected.
strength in this type of application. As a roller or ball
encounters water, there is insufficient film strength
to prevent the element from contacting the race.
This contact, under conditions of extreme pressure,
can cause micro-fractures. Continued exposure to
water can also cause a condition known as hydrogen
embrittlement, increasing the formation of micro-

CHART 1: Effect of water on rolling element life

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 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

Particulate of time will allow estimation of the particulate

contamination’s effect on bearing life. The following
Second to water, the most common contaminant is
chart can be used to make a quick estimate.
particulate. In operation, rolling element bearings
ride on a film of lubricant that is from 0.1 to 1.0
micron thick. Any particulate larger than that can
cause damage to the bearing. Filtering to one tenth ISO CODE MINIMUM MAXIMUM
of a micron is impractical for most applications. 1 0.01 0.02
Even filtering to one micron is difficult. Most 2 0.02 0.04
bearing manufacturers take this into account when 3 0.04 0.08
calculating L10 bearing life. They use the assumption 4 0.08 0.16
that the lubricant will meet the ISO Base-Cleanliness
5 0.16 0.32
Target for rolling element bearings.
6 0.32 0.64
Fluid cleanliness rated per the ISO Code is reported
7 0.64 1.3
as a three-number rating such as 18/16/13. The first
8 1.3 2.5
number (in this example, 18) represents the number
9 2.5 5.0
of particles per milliliter (about an eyedropper
full) of fluid that were greater than or equal to 4 10 5.0 10.0
microns. The second number represents the number 11 10.0 20.0
of particles that were greater than or equal to 6 12 20.0 40.0
microns. The last number represents the number 13 40.0 80.0
of particles that were greater than or equal to 14 14 80.0 160
microns. In the above example, there would be
15 160 320
between 1300 and 2500 particles greater than or
16 320 640
equal to 4 microns, 320 to 640 particles greater than
17 640 1,300
or equal to 6 microns, and 40 to 80 particles greater
than or equal to 14 microns. Each increase in rating 18 1,300 2,500
number represents an approximate doubling of the 19 2,500 5,000
number of particulates. The ISO Base-Cleanliness 20 5,000 10,000
Target for new fluid for rolling element bearing 21 10,000 20,000
lubrication is 16/14/12. 22 20,000 40,000
Most analysis programs report only a two-number 23 40,000 80,000
rating. This two-number reporting is either based on 24 80,000 160,000
an older (pre-1999) reporting method that counted 25 160,000 320,000
5 and 15 micron particles or simply the last two
26 320,000 640,000
numbers of the three-number system. There is a
27 640,000 1,300,000
slight difference between the 5 and 15 micron rating
and the 6 and 14 micron rating of the newer system, TABLE 1: ISO 4406: 1999 Fluid cleanliness
but the practical results are similar. In other words, Codes. Number of Particles per 1 ml of fluid.
the ISO Base-Cleanliness Target for new fluid for
rolling element bearing lubrication, which is 16/14/12,
could also be reported as 14/12. Using this chart is simple. If the analysis report
Knowing the average ISO 4406 numbers for a stated the ISO 4066 as 21/18, for example, cleaning
particular compressor over an extended period the lubricant to the point that the rating improved

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 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

to 15/12 would increase the expected bearing life may react with the additive package in another
300%. Another way to look at this is that the lubricant lubricant. For this reason, do not mix brands of
started at 15/12 and is now 21/18. At 21/18 the lubricant. This may lead to the premature failure of
expected lubricant life is only one third of what it the fluid.
would be at 15/12. Note: Chromium, cobalt, copper, magnesium,
The primary source of particulate contamination in manganese, nickel and iron particulates in an oil
rotary screw compressors is the inlet air. Dirt and sample are indicative of metal wear.
dust making their way through the inlet filter will Additive depletion is also accelerated by the
show in lubricant sample tests as silicon (or silica) presence of water and wear particles. Many of the
and possibly aluminum. While dirt and dust can have additives consist of polar molecules. This makes
different elemental constituents, including magnesium them attracted to solid surfaces such as internal
and calcium, silicon oxides and aluminum oxides are metal components. Some additives are specifically
the most common. designed for this so they will combine with metal
The presence of barium, boron, molybdenum, contaminants, making them easier to filter out of the
phosphorous, and zinc in an oil sample are of less lubricant system. Other (anti-corrosion) additives
concern because they are common additives to will adhere to internal metal surfaces to prevent
lubricants (though increased levels of zinc and corrosion.
copper in subsequent samples could indicate wear
conditions of brass components). If these elements
are found in a sample, where they were not present
in prior samples, it could indicate that the lubricant
was contaminated with another type of fluid. If these
elements are found in the first sample, but are not
in the original lubricant formula, it could indicate
a contaminated transfer pump. It is important to
remember that the additive package in one lubricant

CHART 2: Bearing Life

Factor

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 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

Oxidation expected life when the system is not completely and

thoroughly drained and cleaned. For this reason, it is
Because they are mixed with air at high temperatures
important to remove the fluid while it is still in good
under pressure, all air compressor lubricants will
condition and not wait until it has started to form
oxidize eventually. The oxidation of lubricants
these by-products.
produces a number of unwanted effects. As the
lubricant begins to oxidize, organic peroxides Storage, handling and transferring lubricants affect
will form. As the lubricant continues to oxidize, the cleanliness of the fluid. It is very important to use
alcohols, ketones, and organic acids will form. These only clean, dedicated containers and transfer pumps.
compounds will show as an increase in the Total Do not use one pump for several different fluids.
Acid Number (TAN) on a fluid analysis report. With Even a small amount of residual fluid in a pump can
synthetic hydrocarbon lubricants, an increase in contaminate an entire sump.
TAN of 1 above the lubricant’s base TAN is cause
for alarm and a TAN increase of 1.5 indicates a fluid
on the verge of failure. Varnish and other unwanted
substances quickly follow. With regular mineral oils,
this process can begin after only one to two thousand
hours in a rotary screw compressor. Synthetic
lubricants are more stable than natural mineral oils
and oxidize more slowly. Most full synthetics have an
8000-hour service life rating or more.
Note that Food Grade lubricants behave
differently! Consult the manufacturer to
determine the behavior over time of a specific
lubricant.
When PAO synthetics were first introduced, their
additive packages were not well engineered. As
the anti-oxidant package was depleted and the
fluid reached the end of its service life, the lubricant
could progress from good to completely polymerized
(varnish) in a matter of days. Although newer
formulated additive packages have greatly reduced
this problem, synthetics should still be changed
when they reach their service hour or calendar life,
regardless of sample analysis.
Some of the by-products of a lubricant that is very
near the end of its useful life will likely remain in
the lubrication system after it has been drained. It
is very important to remove as much of the old
lubricant as possible. The additive package of the
new lubricant will react to these by-product as
FIGURE 2: proper collection practices are vital in
contamination, rapidly depleting the additives in the
collecting an accurate sample
new lubricant. It is not unusual for the life of fresh
lubricant to be reduced to as little as 25% of its

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 White paper: THE BASICS OF ROTARY SCREW COMPRESSOR LUBRICANTS

CONCLUSION
Lubricant is a critical component in rotary screw
compressors. Its condition is the key element in
determining the service life of the machine, and it
is constantly exposed to contamination. In order to
maximize the service life of the compressor, follow
these rules:
1. Locate the compressor inlet to draw clean,
cool air.
2. If the compressor is air-cooled, provide clean,
cool air to inlet of the cooling air system.
Keep coolers clean.
3. If the compressor is water-cooled, provide
clean, cool water to the heat exchanger.
Clean or replace the cooler if it becomes
fouled. Fouling restricts heat transfer.
4. Sample the lubricant frequently.
5. Stop the compressor once per week and
check for water in the separator reservoir.
Drain off any water found. In hot and humid
environments, this may have to be done more
often.
6. Inlet filtration is the first line of defense.
About the Author
Clean the inlet filter often and replace when Wayne Perry is Senior Technical Director at
required. Examine the connection between Kaeser Compressors, Inc. An industry specialist
the filter and the airend for leaks to make with more than 30 years of experience in all
certain no ambient air is drawn in behind the aspects of the compressed air business, Perry
filter. Check filter fit for a good seal. is a Qualified AIRMaster+ Specialist for the U.S.
Department of Energy and a former instructor
7. Change the lubricant before it gets near the
for Compressed Air Challenge. He has provided
end of its life. Depleted lubricant left in a
extensive technical expertise in the development
compressor (even a relatively small amount)
of international standards for compressed air
can significantly reduce the service life of the
system assessments and has also worked as a
new lubricant. If the lubricant has started to
Compressed Air Expert for the United Nations
fail, use a lubricant flush prior to changing the
Industrial Development Organization. Perry
fluid.
serves on various technical and standards
8. Properly apply compressors to avoid low duty committees of the Compressed Air and Gas
cycles, keeping temperatures within their Institute. He can be reached at wayne.perry@
designed operating range. kaeser.com.

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Compressors, 9
Technology Meets Tradition
Our compressed air heritage is built on
a century of manufacturing experience.
Generations of quality craftsmanship guide
our engineering principles of efficiency,
reliability, and serviceability.
This tradition of excellence also drives new
technology development. Advances in airend About the Author
design, controls, and system design ensure Matt McCorkle lives in Fredericksburg, VA where
our customers can meet the daily challenges he works as the Manager of Branch Operations
of their manufacturing operations. for Kaeser Compressors. He holds a Bachelor’s
degree in Mechanical Engineering from the US
Each Kaeser product is designed with the Air Force Academy and a Master’s of Engineering
future in mind, but we never lose sight of our in Industrial and Systems Engineering from
roots. Technology needs may change from the University of Florida. Matt has worked as a
year to year, but the need for quality and licensed Professional Engineer and has been a
reliability will always remain. certified energy manager through the Association
of Energy Engineers. He was instrumental in
establishing Kaeser’s nationwide leak auditing
program.

Kaeser Compressors, Inc.

511 Sigma Drive
Fredericksburg, VA 22408 USA
Telephone: 540-898-5500
Toll Free: 800-777-7873
us.kaeser.com
[email protected]

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