Lubrication for compressors

Reciprocating compressors are among the many lubrication  systems we have developed. These devices use the work done by an engine to increase the pressure of air or gas. Besides being used for air compression. They are also used for process applications, i.e. to compress gases like methane/hydrogen, and for various processes related to the extraction/transportation/use of gases coming from oil withdrawal.

The compressors can have one, two or four stages. This factor defines the numbers of points to be lubricated. Lubricated components are:

- the cylinders, in which the pistons reciprocate
- the packing glands/rods

Proper lubrication of packing glands helps to improve and to ensure the seal of the gas area, while the lubrication of the translational motion of the control piston of the cylinder prevents wear and seizing.
The challenge DropsA took up concerned the issues related to low flow rates and high compression ratios, even over 250 bar, to which these machines are subject. Going into more detail, our customer has asked us to create a system capable of reaching high pressures and a low flow rate, all supported by equipment suitable for potentially explosive areas (ATEX).
To address these issues, DropsA designed a lubrication station that consists of two main parts. The first is the "main pumping unit" which includes pumps and reservoir, while the second is the "distribution unit" that includes all the distribution components and accessories.

Two piston pumps were mounted on the main unit (DropsA in-line pump), one operating and the other on stand-by. Generally in this type of high-performance, continuous loop system, the system is equipped with a stand-by (reserve) pump in order to ensure the oil flow, thus avoiding downtime that would lead to a loss of production, or even damage, to the plant.
Safety and control components are located between the pump and the master divider: the PSV (pressure safety valve), the non return valves, the safety valves, the pressure gauges, and it is set up for a digital pressure gauge and a protection filter on the master divider. The master divider, which feeds the two secondary progressive dividers on the lubrication points, has a proximity sensor to control the proper flow. 

The structure is completed by a 100 l fuel reservoir mounted above the pumps so that the suction is under head, preventing air bubbles in the suction and delivery. A heater with a thermostat is also mounted on it to keep the oil temperature constant. It also has a loading cap with filter, a visual level gauge and an electronic one.

Seven balancing valves ensure proper delivery of lubricant on all points. The support of these valves is necessary especially when the back pressure at the lubrication point reaches a differential pressure of at least 70 bar.

The main products used to make this system are the IN-LINE ATEX PUMP, an effective and economical solution used in custom lubrication systems to meet any pressure and flow requirement, and the nickel plated MODULAR PROGRESSIVE SMX DIVIDERS with ATEX marking.