Compressed air is an essential utility across oil and gas operations, from field production sites to major LNG plants. It powers critical control systems, supports gas treatment processes, and ensures the reliable operation of safety systems.
However, not all compressed air is equal. Oil contamination poses significant risks to safety, compliance, and reliability. As a result, the industry is increasingly turning towards oil-free compressor solutions to meet operational and environmental demands.
Is Oil-Free Compressed Air Necessary in Oil and Gas Operations?
Air purity is vital in oil and gas applications, particularly for instrumentation, process control, and gas processing systems. Any trace of oil in the air supply can disrupt sensitive equipment, foul instruments, and compromise critical systems, including emergency shutdown valves.
Oil contamination can cause serious process disruptions, product quality issues, and increased maintenance costs. For example, oil in instrument air lines can cause valves and actuators to stick or malfunction, potentially leading to unsafe process conditions or emergency shutdown failures. In gas treatment processes, oil carryover can foul sensitive membranes and filters, reducing efficiency and leading to costly downtime.
In extreme cases, contamination of safety-critical systems can result in catastrophic operational failures. With oil and gas facilities operating under high uptime expectations, oil-free compressors offer a safeguard by eliminating a major source of contamination and supporting reliable, continuous operations.
Oil-Free vs Oil-Lubricated Compressors: Key Differences
Oil-lubricated compressors use oil within the compression chamber for cooling and sealing. Despite downstream filtration systems, there is always a risk of oil carryover into the air stream. Over time, filters degrade, and even minor oil ingress can cause significant issues in oil and gas environments.
True oil-free compressors are engineered so that no oil enters the compression process. This ensures 100% oil-free air without relying on filtration. In high-integrity facilities like LNG plants, offshore platforms, and major gas plants, oil-free compressors are increasingly specified as the standard to protect operations.
Although the initial capital cost of oil-free systems can be higher, the total cost of ownership is lower in harsh or remote locations. They reduce the need for frequent filter maintenance, minimise unscheduled downtime, and extend the lifespan of critical equipment.
Oil-Free Compressors and Compliance in the Oil and Gas Industry
Compressed air quality must meet strict standards across the oil and gas industry. ISO 8573-1 Class 0 certification ensures that the air is completely free from oil, supporting the high safety and quality standards expected in hazardous operations.
Oil-free compressors assist compliance with standards such as API 614 (Auxiliary Systems for General-Purpose Applications) and meet environmental obligations under Australian regulations, including requirements set by the EPA and Department of Water and Environmental Regulation (DWER WA).
By eliminating hydrocarbon contamination risks, oil-free systems simplify regulatory audits, assist with safety case documentation, and support licensing requirements, particularly where environmental protection and worker safety are paramount.
Debunking Common Misconceptions About Oil-Free Compressors
Historically, oil-free compressors were perceived as expensive and less durable. However, recent technological advancements have significantly improved reliability, efficiency, and lifecycle costs.
Modern systems, such as water-lubricated designs and advanced rotor technologies offer lower operational costs, reduced wear, and longer lifespans. These systems are specifically engineered to perform reliably in demanding environments, delivering energy efficiency and robust performance even under extreme conditions.
The ELGi AB Series, for example, features an innovative water-lubricated design which uses water for sealing, cooling, and lubrication, eliminating the risk of oil contamination. This approach offers superior thermal stability, reduces component wear, and improves energy efficiency. Unlike traditional oil-free compressors that may struggle with heat and maintenance demands, the water-lubricated system extends service intervals and lowers lifetime operating costs, making it ideal for harsh oil and gas environments.
Today’s oil-free compressors are a proven, low-risk investment for oil and gas operators looking to secure operational integrity and reduce maintenance burdens.
Where Oil-Free Compressed Air is Critical in Oil and Gas Operations
Oil-free compressed air plays a vital role across upstream, midstream, and downstream operations:
- Control air for critical valves and actuators — ensuring accurate, reliable actuation in emergency and operational scenarios
- Instrument air — powering SCADA systems, flow meters, pressure sensors, and analytical instruments without contamination
- Gas compression and treatment processes — supporting processes such as nitrogen generation without oil fouling
- Emergency Shutdown Systems (ESD) — maintaining the integrity of vital safety mechanisms
Given the essential nature of oil-free compressed air at each of these points, it is critical to prevent contamination. With oil-free systems, facilities can avoid equipment malfunctions, costly downtime, and potential breaches of environmental and safety standards.
Oil-free compressors are no longer optional for oil and gas operations. They are increasingly critical for protecting operational safety, ensuring environmental compliance, reducing total ownership costs, and maintaining system reliability. As regulatory pressures grow and asset integrity becomes more closely scrutinised, early adoption of oil-free technology positions operators ahead of the curve.
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