For the performance and longevity of compressed air systems, compressor oil is crucial.
Not only does it lubricate moving parts, but it also helps to dissipate heat, reduce wear and seal internal components.
This mishandling of compressor oil maintenance can lead to performance issues, increased maintenance costs and even equipment failure.
This article runs through some common compressor oil mistakes, looking at the consequences of these errors and setting out some best practices for using the product.
Specific mistakes and their consequences
Using the wrong oil type
Compressor oil formulations are engineered for specific applications. Choosing an unsuitable oil – for example, selecting conventional oil when synthetic is required, or using generic lubricants instead of manufacturer-specified products – creates problems. Poor lubrication performance, quicker component degradation and harmful deposit formation are just a few of the potential issues.
Overfilling the compressor with oil
Adequate lubrication is essential, but too much oil creates its own set of problems. Overfilled systems experience what is known as ‘oil carryover’, where excess lubricant enters the air stream and contaminates equipment. This contamination compromises air quality and damages pneumatic tools.
Using too little oil
Operating with inadequate oil levels is a dangerous mistake. Insufficient lubrication creates metal-to-metal contact, and this generates excessive heat and friction, leading to component seizure or bearing failure. The cost of rebuilding or replacing a compressor far exceeds the expense of proper oil maintenance.
Neglecting oil changes
Compressor oil deteriorates over time, losing its viscosity (resistance to flow) and protective properties. Oil life should not be extended beyond recommended intervals, as this allows contaminants to build up and reduces heat transfer efficiency.
Mixing different oil types
Blending different oil types or brands can present the problem of chemical incompatibilities. When different oil types don’t ‘agree’ with each other, the result can be formation, viscosity breakdown or sludge development. These reactions can compromise lubrication and damage components.
Failing to properly filter oil
Oil filters protect air compressor systems by removing harmful contaminants, but they must be properly maintained. Clogged filters allow dirt, metal particles and other debris to circulate and act like sandpaper on components, increasing wear and impacting air quality.
Allowing oil to become too hot
Heightened operating temperatures break down oil molecules, which reduces lubrication effectiveness and promotes oxidation. Varnish and sludge deposits restrict flow and reduce heat transfer. This makes temperature monitoring and proper cooling system maintenance essential.
Further consequences of these mistakes
Reduced compressor lifespan
Compressor longevity is negatively impacted by poor oil practices. Internal components wear rapidly when lubrication fails, leading to premature bearing replacement, seal failure and complete system breakdown. The difference between proper and improper oil maintenance can represent years of service life.
Contamination of compressed air
Oil carryover and contamination affect the entire compressed air system. Poor air quality damages downstream equipment, affects product quality and may contravene industry standards.
Increased maintenance costs
Oil-related failures risk creating a domino effect of maintenance issues. Component replacement, system cleaning and emergency repairs can quickly see costs spiralling. The expense of reactive maintenance typically exceeds proactive care by a factor of three to five.
Potential for equipment damage
Severe oil management errors can cause failures that require complete compressor replacement. Worst-case scenarios include seized rotors, damaged cylinders and burned windings.
Reduced efficiency
Degraded or contaminated oil increases operating friction and reduces heat transfer efficiency. This means the compressor must work harder to deliver the same output, and this will consume more electricity.
Best practices for compressor oil
Let’s conclude with some recommendations for compressor oil use:
Use the correct oil
Always refer to the compressor manufacturer’s specifications. Manufacturers include brands such as Shell and Petronas. Using the right oil type ensures optimal performance and longevity.
Check oil levels regularly
Keep the oil at recommended levels and inspect regularly to spot any issues.
Follow an oil change schedule
This should be based on operating hours and environmental conditions. Don’t stretch oil life beyond its limits.
Use high-quality filters
Replace oil filters at regular intervals to keep the oil clean and free from contaminants.
Monitor oil temperature
Keep an eye on operating temperatures. If oil is consistently overheating, investigate cooling issues or consider a higher temperature-rated oil.
Avoid mixing oils
If oil needs to be switched, fully flush the system before introducing a new formulation.
Training
Ensure maintenance staff are properly trained on compressor oil procedures and understand the impact of neglecting best practices.
