Have you ever been saddled with the responsibility of managing a high end Industrial plant or refinery where the fate of production lies in your every decision?

If you’re running one of the Production plants in Africa or any mechanical inclined industry, the last thing you need is an unplanned shutdown. But a production standstill is exactly what is at risk if you don’t keep an eye on the viscosity of the lubricating oil used in any of the rotary compressors in the plant, with the highest risk of these being the gas compressors. One minute all processes are up and running, and the next there’s a bearing failure and production stops.

It’s not just the cost of lost production either. A compressor failure in a single part of the refinery can cost tens of thousands of dollars a day in lost revenue, with similar amounts to rebuild a compressor, and hundreds of thousands of dollars for a replacement. There’s also the cost of maintaining spares.

Clearly managing lubricant viscosity is critical to maintaining compressor health, but it is a common practice to monitor lubricant viscosity in each major compressor once a month by sending a sample to a lab for testing. For compressors where lubricant comes in contact with methane and other light hydrocarbon gases, the lubricant’s viscosity can break down much more quickly, increasing the risk of failure. Through hard luck, refiners also have found that real-time temperature monitoring is inadequate to monitor lubricant viscosity.

A major Gulf Coast refinery in the United states claims it has solved the problem by moving to real-time monitoring of lube oil viscosity in critical compressors.

“We recognized that in-line viscometers are the best way to know what is happening to the lube oil in our large screw compressors,” says the plant manager. “Further, we have found that in-line lubrication viscosity monitoring offers a cost-effective way to keep track of compressor health.”

The true measure of the health of a lubricant’s viscosity can only be gauged when measured in its natural position with gas vapors dissolved in the lubricant. In addition, monitoring lubricant temperature isn’t sufficient to protect compressor bearings, especially in applications where process starts and stops can occur.

What’s needed is in-line viscosity monitoring to help provide plant operators with real-time data on lubricant in-line viscometers are able to monitor real-time changes in lubricant viscosity, offering a cost-effective way to keep track of compressor health in real time.
viscosity. There is a solution for refinery managers working to keep plants online and producing. New, inexpensive and rugged

Refineries and Compressors

Rotary compressors are used throughout oil refineries in applications ranging from vapor recovery to gas-processing operations. Screw and scroll compressors make up a significant portion of this equipment.

Screw compressors use two reciprocal screws to compress gases. Gas is fed into the compressor by suction and moved through the threads by the rotating screws. Compression takes place as the clearance between the threads decreases, forcing the compressed gas to exit at the end of the screws.

Scroll compressors, often known as spiral compressors, use two interleaved spiral vanes to move and compress fluids and gases. Typically found in intermediate and end-product applications, scroll compressors are valued for their reliability and smooth operation.

The Importance of Lubricant Viscosity

In both types of compressors, lube oil is used to seal the compressor from gas leaks, lubricate moving parts and manage temperature during operation. The condition of lubricant oil is a critical factor in extending a compressor’s bearing life and overall reliability. Monitoring and managing lubricant viscosity can prevent costly breakdowns due to bearing failure. Viscosity also plays a role in energy efficiency, as demand for more efficient compressors is driving the use of lower-viscosity lubricants.


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