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Causes and solutions for oil leakage of air compressor oil separator filter
- Sep 22, 2018 -

In the actual processing, we found that most of the fault complaints are not caused by the quality of oil separator. Then, apart from the oil separator quality problem, what other reasons will cause the oil run off? In practice, we conclude that the following situations can also lead to oil running:

                                               

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1, The minimum pressure valve failure




If there is a leak point in the seal of the minimum pressure valve or the minimum pressure valve is opened ahead of time (usually between 3.5 and 5.5 kg/cm2 due to the different design opening pressures of different manufacturers), the time for the machine to establish the oil and gas tank pressure at the initial stage of operation will increase. At this time, the high concentration of gas and oil mist in the low pressure state will flow through the oil separator in time. Fast, the load of oil separator is heavier, the separation effect is reduced, resulting in large oil consumption.

Solution: overhaul the minimum pressure valve and replace it if necessary.



2, Use of unqualified oil




At present, the common screw air compressor has high temperature protection, and its jumping temperature is about 110-120℃. Some machines use unqualified oil, and when the exhaust temperature is high, there will be varying degrees of fuel consumption (based on this, the higher the temperature, the greater the fuel consumption), the reason is that the high temperature through the oil and gas barrel at the beginning of the high temperature. Some oil droplets have the same order of magnitude as gaseous molecules, and the molecular diameter is less than 0.01 micron. It is difficult for oil separator to capture and separate them, resulting in excessive fuel consumption.

Solution: Find the cause of high temperature, solve the problem of reducing the temperature, as far as possible choose good quality oil.



3, The design of oil and gas separation tanks is not standardized




Some air compressor manufacturers, in the design of oil-gas separation tank, the design of the primary separation system is unreasonable, the primary separation effect is not ideal, so that the oil mist concentration before entering the oil-gas separator is very high, the oil separator load is too heavy, the treatment capacity is insufficient, and the oil consumption is too high.


Solution: the manufacturer improves the design and improves the effect of primary separation.



4, Too much refueling




The amount of refueling exceeds the normal oil level, and some oil is carried away with the airflow, resulting in excessive fuel consumption.


Solution: After shutdown, when the air pressure in the oil and gas barrel is zero, open the discharge valve and discharge the oil to the normal oil level.



5, Oil return check valve damage




If the return valve is damaged (from one-way through to two-way through), the internal pressure of the oil tank after shutdown will pour a large amount of oil back into the oil separator through the return pipe. Next time the machine runs, the oil inside the oil will not be sucked back to the head in time, resulting in part of the oil running out of the air compressor with the separated air. Commonly used in machines not equipped with oil circuit cut-off valve and head outlet outlet check valve.


Solution: check the one-way valve after removal, if there is debris trapped, clean up debris can be, if the one-way valve has been damaged, then replace new products.



6. Improper installation of return oil pipe




When replacing, cleaning and repairing the air compressor, the return pipe is not inserted into the bottom of the oil separator (reference: it is better to be 1-2 mm away from the arc center of the oil separator bottom), resulting in the separated oil can not return to the nose in time, the accumulated oil will run out with the compressed air.


Solution: Stop the machine and adjust the return tubing to a reasonable height after the pressure relief returns to zero (the return tubing is 1-2 mm away from the bottom of the oil section, and the inclined return tubing can be inserted into the bottom of the oil section).



7. Large gas consumption, overload and low pressure use (or the oil separation capacity selected before the machine leaves factory matches the exhaust capacity of the machine too tightly)




Load and low pressure use means that the exhaust pressure of the air compressor does not reach the rated working pressure of the air compressor itself, but basically meets the requirements of some enterprise users. For example, the enterprise users have increased the use of gas equipment, increased the use of gas, so that the air compressor exhaust volume and the user's use of gas can not reach a balance, false. It is assumed that the rated exhaust pressure of the air compressor is 8kg/cm2, but the actual pressure is only 5kg/cm2 or even lower, so the air compressor can not reach the rated pressure value of the machine for a long time, resulting in an increase in fuel consumption. The reason is that, under the condition of unchanged exhaust volume, the oil-gas mixture passes through the oil separator hourly velocity acceleration, oil mist. The concentration is too high, which makes the oil separator load heavier, and ultimately leads to heavy oil consumption.

Solution: it is suggested to contact the manufacturer to replace an oil separator that can match the low pressure use.



8. Oil return line blockage




When the return pipeline (including the one-way valve on the return pipeline and the return oil filter screen) is blocked by foreign matter, the oil condensed at the bottom of the oil fraction after separation can not return to the nose, the condensed oil droplets are blown up by the air flow, and are carried away with the separated air. These foreign bodies are usually caused by solid impurities falling during installation.

Solution: Stop the machine, when the pressure of the oil drum is released to zero, remove all the pipe fittings of the return pipe, and blow out the blocked foreign matter. When installing the built-in oil, pay attention to cleaning the oil and gas drum cover, and pay attention to whether there are solid particles at the bottom of the oil core.