Masters
Synthetic Oil Solutions, LLC offers a complete line of superior
synthetic lubricants for hydrocarbon gas compressors. "SYNTHOSOL™"
lubricants are formulated for specific applications using the
best base oils and only the additives that are needed in a particular
application. This philosophy helps us avoid a "one size fits
all" approach, extends our lubricant life, and the equipment
life to give the customer the best performance available. SYNTHOSOL™
products are not meant to be used in gears, engines, or hydraulic
systems…..they are specifically designed for compressors.
SYNTHOSOL™
products are offered as superior lubricants based on; a severely
hydrocracked mineral oil (semi-synthetics), 100% polyalphaolefins
(PAOs), and polyalkylene glycols (PAGs).
The
hydrocracked (semi-synthetic) lubricants are severely cracked
mineral oil based products; hydrocracking is the process of
reacting a base oil with high pressure, high temperature hydrogen
to remove almost all impurities present in the crude feedstock.
Unlike competitive products that are solvent refined, the hydrocracking
process produces a lubricant with fewer impurities and is a
more "narrow cut" product; meaning less light components
in the base oil. Reduced light component carryover results in
a hyrocracked oil that does not "viscosity thicken"
over time as with a solvent refined product.
Hydrocracked
oils have a lower affinity for water resulting in a lower water
concentration during use. Bearing manufacturers have found that
a lower water concentration in lubricants helps to greatly extend
bearing life. (see attached graph) Properly formulated semi-synthetic
lubricants are suitable for use in natural gas and sour gas
applications when dilution is not severe. Digester gas applications,
which are primarily composed of methane and carbon dioxide with
trace amounts of hydrogen sulfide, also use semi-synthetic lubricants.
Carryover is minimized because of the low volatility of these
materials.
Natural
gas applications containing asphaltines must use a polyalphaolefin
(PAO) or a semi-synthetic oil. These lubricants dissolve the
asphaltines and keep them in solution. Polyalkylene glycols
(PAGs) do not dissolve the asphaltines and their use can result
in plugged oil filters and oil lines.
Heavy
natural gas, refinery waste gas, and vapor recovery gases generate
higher molecular weight hydrocarbon gases. This may result in
increased dilution levels in the lubricant. These applications
require properly formulated polyalkylene glycols (PAGs). There
are several different types of PAGs classified by the monomers
used to produce them. Polyethlene, polypropylene glycol copolymers
limit dilution by hydrocarbons. Depending on the ratio of ethylene
oxide to propylene oxide polymerized to make the lubricant,
dilution can be limited to 10 and 20%. Above this level, the
lubricant becomes saturated.
Some
PAGs have a unique water miscibility characteristic. They are
less miscible with water at high temperatures than they are
at low temperatures. This inverse miscibility can be advantageous
in preventing corrosion in compressor applications where moisture
is present. Polyethylene, polypropylene glycol copolymers are
able to dissolve condensed water at ambient temperatures. This
prevents the corrosion situation where free water is able to
pool in the system during shutdown. Once the compressor restarts
and reaches the normal operating temperature, the lubricant
becomes less soluble with water. This water then vaporizes and
exits the compressor with the discharge gas.
Synthetic
and semi-synthetic lubricants can offer significant cost savings
in process and hydrocarbon gas compressors. Their chemical inertness
and thermal stability can increase drain intervals. The low
volatility of synthetics minimizes vapor phase carryover of
the lubricant and decreases make up oil requirements.
PAGs
resist dilution by hydrocarbons, allowing them to maintain their
viscosity at high discharge temperatures and further improve
the sealing capability. The high viscosity index allows synthetic
and semi-synthetic products to provide lower viscosity when
equipment is started in cold ambient conditions. This helps
increase oil flow and reduces wear at startup. PAOs and semi-synthetic
products that contain minimal amounts of water during use significantly
extend bearing life.
Many
competitive products offer formulations that include active
sulfur based extreme pressure additivies. These additivies are
needed in applications with heavy duty gears where there are
moving parts under very high loads and low speeds where the
surfaces are not protected by a film of lubricant. This is known
as "boundry lubrication". These additivies chemically
react with metal surfaces under boundry lubrication conditions
to prevent welding. In a hydrocarbon gas compressor, the moving
surfaces are protected by a lubricant film; known as "hydrodynamic
lubrication". Sulfur based extreme pressure additives are
usless in compressor application. Bearing manufacturers have
also found that these additives can adversely affect bearing
life. (see attached article from Timken)
SYNTHOSOL™
is formulated specifically for compressor applications, our
philosophy is to use the best, base oils available, and only
the additives that are needed in a specific application. By
providing us with the compressor operating conditions, a complete
gas analysis, and any specific application information, we can
recommend a lubricant that is designed for your particular job
to provide long life for your compressor and fewer oil related
problems.
OIL ANALYSIS
Lubricants used in process and hydrocarbon gas applications
require regular sampling. Proper sampling and analysis insure
that the lubricant retains its original properties, it is also
the best way to determine oil drain intervals. A typical sampling
is every three to six months once a base line is established.
Tests include analysis for corrosion by-products, moisture,
contamination, particle count, particle size and wear metals.
Change in the used lubricant's viscosity, additive levels and
total acid number are critical parameters in deciding when to
change the oil. Oil sample kits can be obtained from Masters
Synthetic Oil Solutions by contacting a representative at (866)
366-5699 Toll Free, or (281) 367-5699. (See Oil Analysis Program
section.)
View
Viscosity Equivalents Graph
