CPI合成螺旋杆式 空气压缩机润滑油 John C. Tolfa CPI 公司.

Presentation on theme: "CPI合成螺旋杆式 空气压缩机润滑油 John C. Tolfa CPI 公司."— Presentation transcript:

1 CPI合成螺旋杆式 空气压缩机润滑油 John C. Tolfa CPI 公司

2 CPI 的合成润滑液 CP-4601- PAO/双酯 (预期寿命8000 小时)
CP-4601-F - PAO/美国食品及药物管理局, 美国农业部认可 (预期寿命4000小时) PARA-4 - PAO/符合美国药品管理规定的产品。是半合成，预期寿命4000小时压缩机油。 CPI 较为纯净的II－双酯类 CPI Engineering Services, Inc. has the most complete line of rotary screw compressor fluid offered in the world. As the major supplier to all U.S. rotary screw air compressor original equipment manufactures, CPI is recognized as a world leader in compressor fluid technology. Now in its 24th year of existence, CPI is aggressively pursuing international markets with our proven compressor fluid technology. All fluids offered by CPI have been developed and formulated to original equipment manufacturer (OEM) operating requirements, and can be 旧的 in any brand of compressor. Viscosity’s and lubricant additives have been designed for compatibility with materials of construction. More important, they are superior to all other brands of synthetic and mineral oil based fluids. Several examples will be presented in order to support this claim. The fluids shown are those offered by CPI. The CP-4601 is a full synthetic PAO/diester blend offering 8000 hours expected life at normal operating conditions. CP F is our FDA/USDA approved lubricant for use where incidental food contact can occur. Incidental food contact means the lubricant cannot deliberately be added to the food. Food Grade approved lubricants are allowed to come in contact with the food product if the amount is no more than 10 ppm lubricant in the food product. The PARA-4 is a "partial synthetic", a blend of USP (pharmaceutical grade) mineral oil and PAO offering 4000 of expected life at normal operating conditions. CP-4200 (not shown) is our premium fluid. A polyolester based lubricant offering more than 16,000 expected life, even at elevated temperatures and pressures. It is typically 旧的 in 高 pressure/高 temperature applications. It is also biodegradable. Finally, Comp Clean II is offered to clean dirty machines for conversion to CPI fluid, and for cleaning varnished or sludge machines.

3 螺杆式压缩机的内部零件图 It is important the function of the compressor fluid be understood to have a full appreciation for the advantages these premium fluid offer over conventional mineral oils. Not just any fluid can lubricate this kind of compressor. The functions of a rotary screw compressor fluid are to: -Lubricate the shaft seals, bearing and rotating screws -Remove the heat of compression -Provide a seal between screws and housing so gas can be compressed without blow-by -Remove contaminants from the system, ie: wear materials -protect against corrosion. The main reason why not just any fluid will do is the harshness of mixing air, which contains oxygen, with oil at elevated temperatures ( °C). Oxidation, which is a chemical reaction between the oxygen in air and the oil is the process by which it degrades so it must be changed out. Mineral oils typically last only 1000 hours under the severe conditions seen in a rotary screw air compressor. CPI long life fluids made from synthetic basefluids were developed to extend the drain interval as much as 16 times.

4 油浴式螺杆压缩机的流程图 气体入口 气体排放 润滑油清理路线 压缩机 空气与润滑油 的隔离器 润滑油与气体 油的注入口 轴承入口 轴承出口
Because the fluid is recirculated in a closed system, from the compressor to the separator, pumped to a cooler, filtered and back to the compressor, it is extremely important that the lubricant maintain its lubricant properties and integrity throughout its useful life. Breakdown of the lubricant or its capabilities will lead to compressor problems. Therefore, it is important to use the best fluid, designed to meet these harsh demands. As we will see CPI Fluids are the best fluids on the market at meeting these requirements and preserving the successful operation of the compressor. 轴封 润滑油冷却剂 热通道阀 润滑油泵 过滤器

5 矿物油产品经常出现的问题 温度太高 温度太低 润滑油不能更换 严苛或恶劣的环境
Mineral Oils are naturally occurring materials derived from crude oil. Although they have been 旧的 for many years as lubricant basestocks, the rotary screw air compressor is a very severe application fluid for these fluids and often fail when one of the following conditions are met. If temperatures are 高, usually above 70°C, mineral oils can thermally degrade due to temperature, particularly when oxygen is present, as in an air compressor. Because mineral oils contain wax, they can become thick or even solidify at temperatures often seen at startup conditions where climates are cold. (Not necessarily true for most of Asia). If a lubricant cannot be changed on a regular basis, or it a system is sealed for life a long life synthetic is the only real answer. One thousand hours of operation is only about one months operating time if the system is operating 24 hours a day, 7 days per week. At this rate, a mineral oil based compressor lubricant would have to be changed out every month! Many compressor operate in applications where hostile or reactive chemicals can be injested with the intake air. The synthetic fluids offered by CPI are more chemically inert, or less reactive with most of these reactive chemicals, and will not degrade as fast as a mineral oil.

6 合成油与矿物油的相对性能比较 合成 矿物 PAO 烷基 双酯 多元醇酯 聚醚类 磷酸酯 硅油 特性 油 苯 (PAG)
粘度－温度的属性. 一般 好 一般 非常 好 好 好 差 极好 低温流动性　 差 好 好 好 好 好 一般 好 抗氧化　　　 非常 好 好 好 极好 一般 一般 好 与矿物油的比较 极好 极好 极好 好 一般 差 一般 差 低挥发性　 极好 好 极好 极好 好 好 好 对漆的影 表面材料的影响 无 无 无 微小 中等 中等 相当大 　微小 水解稳定性　 极好 极好 极好 一般 一般 非常 好 一般 好 防锈性 极好 极好 极好 一般 一般 好 一般 好 添加剂的溶解度 极好 好 极好 好 好 一般 好 差 弹性体的膨胀性 轻微 零 轻微 中等 高 轻微 高 轻微 (丁苯橡胶) Synthetic lubricant basestocks are designed by chemists and chemical engineers to posses many desirable lubricant properties. They are manufactured in chemical reactors, under controlled conditions, so their quality is consistent and they are free of the many contaminants found in mineral oils derived form crude oil. This gives synthetics many advantages listed in this table. As you can see not all synthetic fluids are the same and each has its own, unique characteristics. This comparative data lists the properties that are most important to a rotary screw air compressor fluid. A quick review of the chart shows that there is no one fluid, mineral based or synthetic that meets all these characteristics. However, the PAO basestock 旧的 in CP-4601 and PARA-4 satisfies more of these requirements than any other basefluid type. A PAO based compressor fluid is an obvious choice for CPI long life fluid selection. CP-4200 is also desirable because of its superior oxidative and thermal stability and offers the longest life of any synthetic based compressor oil. * 内部简述

7 CP-4601 令人满意的基本属性 氧化稳定性 热稳定性 低挥发性 更少的积碳生成 粘度稳定性 对添加剂的反应 高粘度指数 较低的总酸价
快速破乳化性 低倾点 浅色

8 ∝合成润滑油的配方 98% 基础油 (聚 烯烃(PAO), 双酯,其他) 2% 添加剂 抗氧化剂 抗锈蚀剂 消泡剂 金属钝化剂
Not all synthetics are created equal. While many synthetic lubricants are made form the same basestocks, the additives 旧的 to enhance its performance are what set fluids apart. CPI lubricants are formulated with propriety additive packages, known only to CPI. Other manufacturers purchase additive packages blended by additive companies for turbine oils and other applications and blend them with PAO to make their compressor fluid, relying the technology of one additive manufacturer. CPI Fluids are formulated from additives form several additive manufacturers, combining the best technology available. It is the additive technology that sets CPI fluids apart from the competition. A typical formulation is shown. The basefluid if typically 98 percent of the formulation, and may be a blend of basestock types. Additives are 旧的 to enhance the performance of the fluid. Antioxidants are 旧的 to protect or inhibit the basestock from oxidation from oxygen in air. These additives are sacrificial, so when they are gone, the fluid is then free to oxidized. Rust and Corrosion inhibitors are 旧的 to coat the metal surfaces, providing a protective layer that keeps water and other corrosive materials from coming in contact with the metal surfaces where they can cause corrosion. Defoamants are additives that cause any foaming that is generated in the separator to collapse, so fluid is not carried over into the system. Metal 通过ivators are also additives that coat metal surfaces, like copper, brass or bronze that can catalyze or speed up the oxidation reaction of the fluid.

9 辛辛那提Milicron 热稳定性测试 润滑油 粘度, cSt. TAN 铜 钢 油泥 CP-4601 新的 41.08 0.130 1 1
旧的 不 PAO-U 新的 旧的 是 (大口杯底部) PAO-S 新的 旧的 不 PAO-P 新的 旧的 不 PAO-R 新的 旧的 是 自动变速箱用油 新的 旧的 不 乙二醇/酯 新的 旧的 不 20wt. 矿物油 新的 旧的 是(在控制器上结块) Competitor oil companies market their PAOs as being "as 好 as CP-4601" simply because their compressor oil is PAO based. To them, this makes them equal. These comparisons shown prove 不t all formulations are equal. These accelerated laboratory tests are designed to model real world situations for comparison between fluids. As shown here, 无 of the competitor's PAOs outperformed CP-4601 in this thermal stability test designed to stress the fluid oxidatively as well as thermally. The more resistant to heat and oxidation, the longer the fluid will properly lubricate the machine, without allowing sludge and varnish to form. The comments relating to the steel and copper catalysts relate the amount of staining observed on each surface. The more staining, the more oxidation is taking place at that surface, and the quicker the fluid will break down. ( 1 is least staining , 5 is most staining). Other commonly 旧的 fluids like ATF, 20 wt. motor oil and the polyglycol, ester 旧的 by Sullair and Ingersoll Rand were also included in this test. It can clearly be seen that the CPI Fluid outperformed all the competitors. So why are they saying their fluid is the same as CPI, when the CPI fluid displays the least amount of viscosity and total acid number increase, both properties that are a result of oxidation.

10 螺杆式压缩机的测试 粘度增长, % 操作时间（小时） 排气温度 220-230°F 周围温度120-130°F 压力 100 PSIG
R & O 涡轮用油 CP-4601 双酯 PAO-1 PAO-2 自动变速 箱用油 粘度增长, % This accelerated test further confirms CP is far superior to competitors PAO formulations. This compressor operating at a discharge temperature of 110°C, accelerates the oxidation and ultimate failure of the compressor fluid. CP lasted almost 50% longer than the nearest competitor. Non synthetic performed noticeably worse, as expected. CP-4200 was also run in this test and after 12,000 hours of operation, it still had not failed. No other fluid ever run in this test has coke close to this performance. This test usually translates to 4 to 5 times more life in the actual field application. 操作时间（小时）

11 生锈测试(Rusty Nail Test) 等级 润滑油 空气 油 水 通过／失败 1 CP-4601 通过 通过 通过 通过
等级 润滑油 空气 油 水 通过／失败 1 CP 通过 通过 通过 通过 4 样品　 U 失败 通过 失败 失败 5 样品　-S 　　　　通过 通过 通过 *通过 2 样品-R 　　　　 通过 通过 通过 通过 3 PAO-P 通过 通过 失败 失败 8 自动减速箱用油 通过 通过 通过 *通过 6 聚醚/聚酯 　　　　失败 通过 失败 *失败 7 20wt. 发动机油 通过 通过 失败 *失败 Accelerated corrosion tests were also 旧的 to compare the ability of CP-4601 to resist rust and corrosion to iron surfaces. As shown, some of the competitor's PAOs do not fare as well. Polyglycols such as Sullair' Sullube 32 and Ingersoll Rand's Ultracoolant, typically do 差ly, as do most mineral oils. While ATF 通过ed this test, as we will see, it forms an emulsion that does not allow it to separate from water. * 乳化形成,沉淀率

12 CP-4601 旋转式螺杆压缩机与真空系统 延长换油间隔４到８次 较低的油挥发性 更低油耗 较少的油泥和结胶形成 更低的维护费用
延长轴承寿命 CP-4601 is our most popular fluid because of it 极好 long, life, and compatibility with systems designed for use with mineral oils and is easy to convert systems that previously ran on mineral oils to this fluid. Many of the advantages discussed in this next section apply to all CPI Fluids. CP-4601 is 旧的 not just 旧的 as a rotary screw compressor oil, but performs well in rotary vacuum applications. Several key features and advantages will be discussed to performance features, and cost advantages such as extended drain intervals, lower volatility and carryover, and cleaner operation resulting in less maintenance and better operating efficiency. They will be discussed in more detail..

13 CP-4601价格性能比 更广泛的工作温度范围 更长的换油周期 降低润滑油消耗 延长设备寿命
Cost performance benefits over mineral oils are listed. Wider Operating Temperature Range means the same fluid can be 旧的 over a wide operating temperature range and energy savings can be realized in cold climates during start-up.

14 温度极限的比较 矿物油 CP-4601-46（聚烯烃） 聚醚类 -80 -40 0 100 200 400 600 温度, °F
The graphs shown illustrate the relative operating temperature range a mineral oil , PAO and Polyglycols are capable of operating continuously . The extremes of each graph indicate intermittent service. Synthetic fluids offer better performance at both 高 and low operating temperature. As previously stated, CPI compressor lubricants are more resistant to degradation due to 高 temperatures seen in air compressor application, and therefore last longer. In cold climates, the low pour points of synthetic basestocks allow easier startup. 温度, °F

15 随着温度而改变的粘度值 上好的流体 矿物油 CP-4601-46 ISO VG 增加的保护 40 100 温度, °C
Another key feature of synthetics is their 好 viscosity index characteristics. CP-4601, as with all CPI synthetics, lose less viscosity with increasing temperature than mineral oils. This offer more viscosity at the 高er temperatures seen at bearings, providing better fluid films for lubrication and more viscosity at the rotor tips, offering better sealing for improved efficiency. Less viscosity at lower temperatures during startup also offer energy savings. 增加的保护 温度, °C

16 CP-4601价格性能比 更广泛的工作温度范围 更长的换油周期 降低润滑油消耗 延长设备寿命
Longer Drain intervals offer less fluid to be purchased and less fluid to be disposed of. Maintenance costs due to labor savings due to fewer oil changes costs are also reduced.

17 润滑油的氧化 (O2) (温度) 添加剂的分解 = (紫外线) (金属) 氯仿的可溶物 沥青质/ 胶质（油泥） 己烷可溶物 固体 聚合物 +
　　粘度增加　 (聚合物) + 酸 (酮) Oxidation degrades lubricants, and is the main reason why compressor fluids must be changed. Oxidation is a chemical reaction, as described on this page, that eventually degrades a lubricant beyond its usefulness. Many undesirable by products are produced that can interfere with the operation of the system. Many of these by products are in the form of solids that can deposit within the system as varnish and sludge. By inhibiting the oxidation reaction in a synthetic basefluid, long operative life can achieved. 设计的配方来使固体及粘度的增加最小化

18 氧化稳定性 These graphs show the improved oxidative stability of properly inhibited synthetic basestocks vs. and inhibited mineral oil. The purity of synthetic basestocks and their inherent oxidative stability allow drain intervals far beyond mineral oils.

19 CP-4601价格性能比 更广泛的工作温度范围 更长的换油周期 降低润滑油消耗 延长设备寿命
Not only does longer life allow less oil to be purchased, but low volatility and less carryover also mean less lubricant is consumed.

20 加氢处理的（HVI）半合成油, PAO 合成油和矿物油 ISO 68 的挥发性比较
These graphs illustrate the superior low volatility characteristics over mineral oils. Low vapor pressure due to increased thermal stability, and purity of synthetic basestocks mean less oil carries over past the oil separator. Less oil is consumed by the compressor and less oil ends up down stream to interfere with downstream equipment and operations. 矿物油 重量损失百分比 (22 小时　 在 100°C)

21 CP-4601性能价格比 更广泛的工作温度范围 更长的换油周期 降低润滑油消耗 延长设备寿命
CPI synthetic lubricants also extend equipment life

22 粘度与工作时间的函数—— 合成油与矿物油的比较
粘度, cSt 70 60 50 40 矿物油 While many fluids meet equipment manufacturer’s viscosity requirements when the fluid is 新的, many experience an increase in viscosity due the thermal and oxidative degradation and volatility. CPI synthetic fluid remain in grade throughout their life, assuring proper viscosity and lubrication of bearings. Energy savings is also achieved since increased viscosity as shown with the mineral oil means more power is necessary to drive the compressor. CP-4601（聚烯烃） 时间 (小时)

23 ASTM D-1401-84的破乳化性实验 润滑油 新的/旧的 Sep. Time/Emul. Time
CP 新的 <1 min/Good Sep. . 旧的 <45 sec/Good Sep. PARA-4 新的 <2 min Good Sep. 旧的 <2.5 min Good Sep. PAO U 新的 3 min 30 sec/Good Sep. - Lube Cloudy 旧的 1 min 30 sec/Good Sep. PAO S 新的 4 min/Emul Formed 旧的 2 min/No Emul, Water in Lube PAO P 新的 >30 min/No Sep. 40% Emul. 旧的 2 min/Lube very cloudy, Water in Lube 自动变速箱用油 新的 >30 min/No Sep. 88% Emul. 旧的 5 min/Lube Cloudy 乙二醇/酯　 新的 8 min 45 sec/25% Emul. Water Drops in Lube 旧的 5 min 30 sec/15% Emul. Lube very Cloudy 20 wt 发动机用油 新的 10 min/15% Emul Lube very Cloudy 旧的 >30 min/Some Sep. Emul in 50% Water & 25% of Lube The demulsibility tests shown here illustrate just how 好 CP-4601 is at separating from water. This is not only important to bearing life, also has proven to reduce carryover past the separator element and aid with the separation and disposal of oily condensate in aftercoolers. From these few simple tests, it can be concluded that while others try to emulate the proven performance of CP-4601, they all fall short. No one fluid meets the desirable characteristics of a rotary screw compressor fluid better than CP-4601.

24 影响润滑油寿命的条件 维护习惯 没有移走（完全换掉）先前的已氧化润滑油 操作条件 环境中的污染物 高温 高压 臭氧 氧化氮 氨 酸
金属加工的添加剂 As with all lubricants there are conditions that can shorten any compressor fluids life. Obviously it is imperative that fluid be changed before they begin to severely oxidize ( ie: sludge and varnish) and previously oxidized should be removed by complete draining of the machine. Operating at elevated operating temperatures, ( above 85°C) accelerate the oxidation of any fluid and will be discussed on the next page. Certain environmental contaminants ingested with the intake air can also accelerate the degradation of any fluid. When possible remote air intakes should be 旧的 to avoid ingesting reactive chemicals and solvents.

25 在100psi的压力下排气温度与寿命的对比 As previously stated, elevated discharge temperatures will reduce any lubricant's life. This table gives a relative comparison with CPI fluids will see half its useful life reduced with every 10°C increase in discharge temperature. THIS IS TRUE FOR ANY COMPRESSOR LUBRICANT, NOT JUST CPI FLUIDS.

26 润滑剂的寿命与排气温度 预期寿命, 小时 排气温度, °F CP-4601 CP-4600 8000 6000 4000 2000
This graph provides yet another illustration of the effects of discharge temperature on fluid life. Note that the rate of life is lessened with temperature exponentially. CP-4600 排气温度, °F

27 不要混合不同的润滑油 基础油之间的相溶问题 添加剂之间相溶的问题 如果相溶使其表现如同最糟的液体 矿物油会缩短合成油的寿命 润滑液
可能会产生乳化现象和粘度降低 添加剂之间相溶的问题 可能会产生沉淀 可能妨碍添加剂系统的性能 如果相溶使其表现如同最糟的液体 矿物油会缩短合成油的寿命 润滑液 可能产生泡沫 Self explanatory

28 Use Of CPI Comp Clean II 清净液的使用
清洗机械中的结胶沉淀物 移走大量剩余的旧油 (污染物) 延长设备寿命 延长油的寿命 节约能源 CPI Comp Clean II was developed to allow proper conversion of compressors to CPI Fluids from mineral oils and other synthetics. It is important the compressor is free from any varnish or sludge left behind from the previous lubricant. These deposits will depleted the antioxidant additive package of the next lubricant fill, thus reducing its life. To assure maximum life from CPI Fluids and receive the other benefits listed, be sure to use Comp Clean II. Comp Clean II cleans dirty, varnished compressors allowing more efficient operation and energy savings. A dirt separator element robs the compressor of power, about 5 horsepower for every 3 psi drop across the element.

29 CPI 合成油与生态环境 无毒无危险性 更少的废液处理 比矿物油容易再回收 无危险物料或材料需排放（废液处理）
Self explanatory Product features and benefits are summarized for each of the CPI Fluids discussed in this presentation.

30 CPI PARA-4 美国药物管理规定认可的ＰＡＯ与矿物油的半合成调制油
4,000小时 使用寿命 部分合成－市场的需求 廉价的 寿命长 易处理 与塑胶管兼容 易破乳化

31 CP-4600-F 聚烯烃（食品级合成润滑油） 4,000 - 6,000小时使用寿命* 合成 –市场的需求 破乳化
低的润滑油消耗（携出） 易处理（废液的排放） 与塑胶管兼容 寿命长 *可能在一些运用中较少

32 CP-4601 PAO/双酯的调制油 8,000小时 使用寿命 合成 –市场的需求 破乳化 低的油品消耗（携出） 易处理（废液排放）
与塑胶管兼容 寿命长

33 CP-4201 系列 多元醇酯（Polyolester)
16,000 小时使用寿命 无结胶现象 极长的使用寿命 可生物降解 破乳化 适合市场需求 低的油品消耗（携出）