your global specialist

Industrial sector

Availability under
extreme conditions.
Speciality lubricants for oil refineries
and petrochemical plants
 Speciality lubricants for the cement industry:
Increased efficiency, productivity and reliability
The speciality lubricant –
a key component in oil refinery operation

A key component in oil refinery operation 3 In any refinery, the reliability of “rotating” equipment is crucial to A major contribution to the functional performance of your
efficient, cost-effective production. This includes, for example, rotating equipment is provided by the lubricant. This
Speciality lubricants for process gas compressors 4 gas and air compressors, ball valves, centrifugal pumps, contribution may be small in size – but it has a substantial
mechanical seals, gearboxes and screw connections. effect, as optimised component lubrication can increase the
Speciality lubricants for other applications 6 safety and efficiency of your plant operation. This applies not
Any standstill or even just impeded performance of one of these only to older plants - optimised lubrication can also make new,
Air compressors 6 critical components will significantly affect the profitability of your advanced facilities significantly more efficient.
plant.
Screw connections, ball valves 7

Chemical pumps – rolling bearings, mechanical seals, gearboxes in cooling towers 8 Facts on refineries
A large refinery can convert up to 16 million tons of crude oil per The petrochemical industry provides the link between the mineral
Desulphurisation systems, products for maintenance 9 year into a wide variety of products. oil industry and the chemical industry. The crude gasoline
produced in the refineries is converted into products such as
The booming Asian refinery sector combined with the continued ethylene and propylene, which are then used in the production of
growth of Europe‘s petrochemical industry in recent years has led plastics, cleaning agents, paints, colorants and synthetic fibres.
to a much higher demand for high-performance lubricants. Crude gasoline can also be processed into aromatic compounds,
i.e. hydrocarbons such as benzene, toluene and xylene, which are
used in the production of plastics or insecticides.

Ambient conditions in refineries are taxing and include extreme

temperatures, strong effects stemming from chemicals and high
physical requirements.

Klüber Lubrication has developed speciality lubricants for these

demanding conditions. Depending on their application, they
offer the following benefits:

– Higher productivity due to longer equipment service life

– Longer component life due to excellent wear protection
– Reliable plant operation as lubricants are resistant to
media

On the following pages you will find a selection of products that

have been tried and tested for the lubrication of components in
oil refineries with consistent success.

2 B152001002 / Edition 09.15 3

Speciality lubricants for process gas compressors

Each individual compressor in your refinery makes a valuable contribution to your annual production result. Compressors are the
most critical and cost-intensive element in your plant and require heightened maintenance attention. An investment that pays off

Switching over to a high-performance speciality lubricant pays

Two factors are of decisive importance when selecting a compressor oil: off: although purchasing costs may seem higher at first, less
maintenance and longer compressor life may already mean
The right oil The right viscosity less strain on your budget in the medium term.

The base oil must match the composition of gases to Another factor to be determined is optimum oil viscosity,
Example:
prevent most interaction between the compressor oil which depends on the operating conditions as well as on gas
Following thorough consultation with our experts, a well-known refinery operator decided to switch his compressors over to
and gas flow.This is a factor that is often neglected in composition. Based on these parameters, the specialists from
Klüber Summit PGS 100. This enabled him to save approx. 127,400 EUR per year with a single screw-type compressor.
refineries, leading to very short maintenance intervals and our Compressor Competence Centre determine optimum oil
high wear, for example on plain bearings. viscosity.

Before changeover After changeover to

Klüber Summit PGS 100

Lubricant costs 5,900 EUR 12,800 EUR

To give you a first overview, this table contains the most important compressor oils for use in oil refineries. In-depth consultation with –– per oil change 12 × 5,900 EUR 1 × 12,800 EUR
our experts is essential to ensure selection of the perfect oil. –– per year = 70,800 EUR = 12,800 EUR

Product Base oil Kinematic Notes and benefits Maintenance per year 160 hrs 65 hrs
viscosity Maintenance cost per year 160 hrs × 40 EUR 65 hrs × 40 EUR
DIN 51562-1 at
= 6,400 EUR = 2,600 EUR
40 °C, [mm²/s]
approx.
Spare parts and 12,000 EUR 2,400 EUR
Klüber Summit synthetic –– For lubrication of reciprocating and screw-type compressors for natural gas
NGSH-68 hydrocarbon 68 –– Good anticorrosive characteristics backup compressor, (assumed service life
NGSH-100 100 –– Effective corrosion protection also with sour gas (hydrogen sulphide) cost per year 40,000 op. hrs.)
NGSH-150 150
NGSH-220 220
Loss of production 700,000 m3 gas per year 140,000 m3 gas per year
Klüber Summit polyglycol oil –– For lubrication of reciprocating, screw-type and rotary vane compressors
PGS 68 68 for natural and process gas
PGS 2 85 –– Compared to mineral oils, the products are very resistant to dilution and Cost of production loss 700,000 m3 × 0.1 EUR/m3 140,000 m3 × 0.1 EUR/m3
PGS 100 100 absorption by hydrocarbon gases. = 70,000 EUR = 14,000 EUR
PGS 150 150
Klüber Summit polyglycol oil –– For lubrication of propane gas compressors, e.g. refrigeration compressors Total cost 159,200 EUR 31,800 EUR
PGI 68 68 –– Compared to mineral oils, the products are very resistant to dilution and
PGI 100 100 absorption by hydrocarbon gases.
PGI 150 150 Cost saved – 127,400 EUR
Klüber Summit polyglycol oil –– For high-pressure reciprocating compressors compressing natural gas,
NGL 444 79 carbon dioxide or process gas
NGL 555 100 –– Highly resistant to dilution and absorption by gases containing hydrocarbon
NGL 777 150 and good chemical resistance to process gases
NGL 888 220 –– Very high viscosity index and, thus, small viscosity change over a wide
temperature range
–– Very good wear protection leading to longer component life
Klüber Summit ester oil –– For process gas compression without damage to downstream metal
DSL-100 XM 100 catalysts
DSL-125 XM 125 –– Approval for hydrogen compression at U.O.P., USA

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Speciality lubricants for other applications

Air compressors Screw connections

Product Base oil Kinematic Notes and benefits Product Product characteristics Notes and benefits
viscosity
Klüberpaste HS 91-21 Black, easy-to-spread –– Efficient assembly due to constant preload forces for screws of different
DIN 51562-1 at
high-temperature paste with a sizes and materials
40 °C, [mm²/s]
new type of –– Screws easy to undo even when subject to high temperatures for a long time
approx.
combination of solid lubricants –– High purity means less strain on the screw connection as product is
Klüber Summit synthetic –– Low maintenance and operating costs due to long oil change intervals of for the assembly lubrication of virtually free from chlorine, fluorine and sulphur
SH 32 hydrocarbon 32 up to 10,000 operating hours in oil-injected screw-type compressors screw connections
SH 46 46 –– Easy changeover from mineral oils due to neutral behaviour of the oil
SH 68 68 towards seals
SH 100 100 –– Low evaporation rate leading to clean compressed air and clean
compressed air lines. Prevention of unnecessary cleaning expenses and
pneumatic valve downtime due to gumming Ball valves
–– Low formation of oxidation residues in the oil circuit enabling low
operating costs due to long oil filter and oil separator lifetimes Product Product characteristics Notes and benefits
Klüber Summit polyglycol oil –– Easier switchover of compressors that were previously running with
NONTROP GB 3 G Base oil: mineral –– Very good resistance to hydrocarbons such as propane, butane, ethane
Supra 32 38 polyglycol oils due to good oil miscibility
Thickener: silicate –– Good adhesion to the friction point
Supra Coolant 55 –– Low maintenance and operating costs due to long oil change intervals of
NLGI grade 3 –– High thermal stability
up to 8,000 operating hours in oil-injected screw-type compressors
–– Neutral towards copper and its alloys
–– Good soil dissolving properties due to the ester content keeping the oil
–– Very good load-carrying capacity with solid lubricants
circuit clean and preventing cleaning costs
–– Low formation of oxidation residues in the oil circuit leading to low UNISILKON L 641 Base oil: silicone oil –– Very good wetting
operating costs due to long oil filter and oil separator life Thickener: PTFE –– Operational smoothness due to the good viscosity-temperature behaviour
–– Very good resistance to cold and hot water and steam
–– High thermal stability
–– Good sealing effect
–– Neutral behaviour towards metal, elastomers and plastics
Klüberalfa PFPE / PTFE grease –– High operational reliability in facilities and components used with
YV 93-302 / 93-1202 NLGI grade 2 gaseous oxygen
– due to wide compatibility with customary materials
– due to wide service temperature range
Synthetic cleaning concentrate for compressors, hydraulic systems, gearboxes –– Multiple uses as sliding agent for industrial processes involving oxygen,
air, carbon dioxide, inert and other gases as well as their condensates
and other oil circulation systems –– May also be used for liquid-oxygen equipment
–– Individual batch BAM certificates
Product Product characteristics Notes and benefits
Klüber Summit Varnasolv synthetic –– Low maintenance and cleaning costs due to effective cleaning of varnish
and carbon build-up without disassembly of the compressor unit
–– Application during operation, hence no compressor shutdown required
for cleaning
–– Easy application Klüber Summit Varnasolv is neutral towards seals when
mixed with oil at a concentration of 10 %
–– Cost-saving operation and maintenance of the cleaned compressor unit
due to higher equipment efficiency or longer oil life

6 7
Speciality lubricants for other applications

Chemical pumps – rolling bearings Desulphurisation systems

Product Product characteristics Notes and benefits Sulphur removed from crude oil is solidified into pastilles by
BARRIERTA KM 192 PFPE / PTFE grease –– Higher component availability over wide service temperature ranges means of a Rotoform system.
NLGI grade 2 where there is contact with aggressive chemicals due to long grease life The rolling bearings used in this system require a high-
–– Improved component performance temperature grease that is resistant to sulphuric components.
– due to low start-up torques even at low temperatures
– due to good speed compatibility
– as friction coefficients are largely unaffected by temperature
Product Product characteristics Notes and benefits
BARRIERTA L 55/2 PFPE / PTFE grease –– Higher plant availability and less maintenance
NLGI grade 2 – at very high operating temperatures up to 260 °C
Mechanical shaft seals – when exposed to aggressive chemicals and vapours

Product Base oil Kinematic viscosity Notes and benefits

DIN 51562-1 at
40 °C, [mm²/s] approx.
Products for maintenance
Klüberfluid NH1 4-005 synthetic 5 –– Higher process reliability as product has been
hydrocarbon oil tested and is recommended by Eagle Burgmann,
the industrial sealing technology expert Product Product characteristics Notes and benefits
PARALIQ P 12 white oil 20,5
Klüberbio Z 2-5 Fully synthetic, highly liquid –– Eco-friendly due to biodegradability
Klüberoil 4 UH1-15 AF synthetic 18
rust remover with strong –– Easy handling as product is supplied ready for use and easy to spray
hydrocarbon oil
penetrating effect –– Reduces need for cleaning, as product is fully synthetic and shows no
Klüber Summit DSL 32 ester oil 32 tendency to gumming
–– Less maintenance required as product combines cleaning, lubricating and
Klüber Summit PGS 10 A polyglycol oil 8
anticorrosive effects

Gears in cooling towers Oil Condition Analysis

Product Base oil Kinematic viscosity Notes and benefits Product Product characteristics Notes and benefits
DIN 51562-1 at
KlüberMonitor – Oil Condition Lab analysis to determine the –– Oil Condition Analysis provides information on the current condition of an oil
40 °C, [mm²/s] approx.
Analysis condition of a –– Reliable: if performed regularly, the analysis reduces the risk of expensive
Klübersynth synthetic –– Synthetic high-performance gear oils used lubricating oil components or systems breaking down
EG 4-150 hydrocarbon oil 150 –– Scuffing load capacity acc. to API GL 4 –– Highly effective: useful lubricant life is maximised
EG 4-220 220 –– Miscible with mineral oils –– Convenient use: set supplied for sampling and shipment; standardised,
EG 4-320 320 –– Very good corrosion protection easy-to-read and comprehensible report with recommendations
EG 4-460 460 –– Resistant to ageing –– Detailed product expertise available at Klüber Lubrication: professional
EG 4-680 680 interpretation of results
EG 4-1000 1000

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The right lubricant at the
right place at the right time

Systems for automatic lubrication

We at Klüber Lubrication understand ourselves as a solution technology are available with standard, long-term or high-
provider. We not only supply high-performance oils and greases, pressure greases, standard or high-temperature chain oils
but also “intelligent packages” for automatic lubrication of your and special oils and greases for the food-processing industry.
machines and components. Selected lubricants covering a wide We are also able to supply other lubricants in automatic Publisher and Copyright:
range of typical applications are available in automatic lubricant dispensers on request and for higher order volumes, provided Klüber Lubrication München SE & Co. KG
dispensers for single-point lubrication. These tried-and-tested they have been tested and approved for use – please contact
systems based on electromechanical or electrochemical your Klüber Lubrication consultant for details. Reprints, total or in part, are permitted only prior
consultation withKlüber Lubrication München SE & Co. KG
and if source is indicated and voucher copy is forwarded.
Your benefits at a glance
The data in this document is based on our general
Profitability Reliability experience and knowledge at the time of publication
and is intended to give information of possible
Continuous production processes and predictable maintenance Automatic lubrication systems from Klüber Lubrication ensure applications to a reader with technical experience.
intervals reduce production losses to a minimum. Consistently reliable, clean and precise lubrication around the clock. Plant It constitutes neither an assurance of product
high lubricant quality ensures continuous, maintenance-free availability is ensured by continuous relubrication of the application. properties nor does it release the user from the
long-term lubrication for high plant availability. Continuous supply obligation of performing preliminary field tests with
of fresh lubricant to the lubrication points keeps friction low and Lubrication with Klübermatic may help to prevent up to 55 % the product selected for a specific application. All
reduces energy costs. of rolling bearing failures data are guide values which depend on the lubricant’s
composition, the intended use and the application
Lubrication with Klübermatic can reduce costs by up to 25 % method. The technical values of lubricants change
depending on the mechanical, dynamical, chemical
From low-cost to high-tech – automatic systems and thermal loads, time and pressure. These
for all requirements changes may affect the function of a component.
Safety We recommend contacting us to discuss your
Klüber Lubrication offers you the following technological solutions: specific application. If possible we will be pleased to
Longer lubrication intervals reduce the frequency of maintenance – freely adjustable lubrication increments between provide a sample for testing on request. Products
work and the need for your staff to work in danger zones. 1 and 12 months from Klüber Lubrication are continually improved.
Lubrication systems from Klüber Lubrication can therefore – range of speciality lubricants Therefore, Klüber Lubrication reserves the right to
considerably reduce occupational safety risks in work areas – self-contained or machine-controlled lubrication systems change all the technical data in this document at any
that are difficult to access. (time control with programmable controller) time without notice.
– combination of tried-and-tested Klüber Lubrication lubricants
Lubrication with Klübermatic can decrease the risk of accidents with proven automatic lubricant dispensers Klüber Lubrication München SE & Co. KG
by up to 90 % Geisenhausenerstraße 7
81379 München
Germany
Klübermatic FLEX Klübermatic NOVA Klübermatic STAR VARIO Klübermatic STAR CONTROL
Local first-instance court Munich, Germany
Certificate of registration 46624

Flexible use – and for For applications subject Precise and adjustable lubricant Externally controlled single-point
lubrication points with to wide temperature metering relubrication
high requirements fluctuations

10 11
www.klueber.com

Klüber Lubrication – your global specialist

Innovative tribological solutions are our passion. Through personal contact and consultation,
we help our customers to be successful worldwide, in all industries and markets. With our
ambitious technical concepts and experienced, competent staff we have been fulfilling
increasingly demanding requirements by manufacturing efficient high-performance
lubricants for more than 80 years.