Compressor Filter & Maintenance Knowledge Center

The #1 reason compressor fluids fail and need to be replaced is acids that are not cleared by the compressor. Acids are found in all compressor fluids and are destructive catalysts that reduce the fluid’s useful life by accelerating oxidation, additive depletion and the degradation that impacts fluid performance. You can slow these destructive forces and increase fluid service life by maintaining low fluid acid levels.

First of all, compressor Fluids have the single greatest impact on compressor maintenance costs. High quality synthetic compressor fluids can be very expensive. The fluid’s performance impacts the reliability and service life of all the compressor’s most costly components (Air-end Bearings and Seals, Coolers, Air-oil Separators, Oil-stop Valves, etc.).

The Ultra-fine clearance-size particles less than 15 microns are the most destructive to compressor internals. Smaller Ultra-fine solids are able to penetrate these clearances. They interfere with the oil films where lubrication occurs. By contrast, this is unlike the larger solids that are too big to fit into tight bearing clearances. Studies show that Ultra-fine solids left in the oil by the OEM’s full-flow compressor filter can dramatically increase bearing wear rates, and reduce bearing (Air-end) life as much 75%!

Oxidation, Ingestion from the atmosphere, and Residual Contamination from the previous oil fill. Fortunately, successful acid prevention and removal strategies exist which are extremely effective at controlling fluid acid levels.

Less than 1% of a compressor fluid has turned acidic when the oil reaches its condemning limit for TAN (Total Acid Number).  More than 99% of that oil is fit for continued use when most compressor fluids are replaced.

Yes. Most high quality synthetic compressor fluids can remain in service indefinitely. However, they must operate in normal environments and be maintained in a proper manner. Use proper contaminant controls and lubricant conditioning techniques. As a result, your compressor fluid’s physical and chemical properties can be safely maintained within its normal acceptable limits. Finally, be sure to address the compressor filter regularly.

In short: oil analysis. It is the best and only method for determining compressor fluid replacement. Oil analysis provides critical information about the oil’s actual physical and chemical condition, and enables users to know precisely if, and when, their oil has reached the end of its useful life and needs to be replaced. Time-based methods that recommend changing the fluid based on runtime or the calendar, are only a best guess at the oil’s condition, and ignore reality and the impact of each compressor’s unique operating environment.

To Sell More Oil. OEM oil sales is the most profitable portion of their business, and the OEMs’ long standing business model is designed to maximize oil sales (user oil purchases). OEMs are opposed to any maintenance strategies or technologies that increase oil service life and reduce their oil sales.

1. Compressor Fluid.
2. Bearings.
3. Air-oil Separators.

Additionally, ultra-fine metal solids are present in compressor fluids. They accelerate oil degradation, bearing wear, and separator fouling. Additionally, they prematurely reduce useful life and drive up compressor maintenance costs.

Reliability Centered Maintenance (RCM), also known as Condition-based or Proactive Maintenance. It is the leading maintenance strategy for companies wanting to minimize their compressor maintenance costs. RCM strives to proactively eliminate the root causes of component failure. Users and owners perform maintenance based on a component’s actual condition or need. They do so instead of using a predetermined time schedule recommended by those trying to sell more fluids and parts. Lastly, RCM has been adopted by many of the world’s largest compressor users.