Manufacturers Replacement 635660 Compressor Air Oil Separator

Analysis of separator failures

• Oil residue inside separator

More than 5 mm of oil in the internal base / bowl of the separator is due to

a fault in scavenging.

Determine cause of fault, rectify and re-use separator if not damaged, blocked or aged.

• Saturated separator

Under normal circumstances the wet band, more easily seen on the outer surface of the white filter media than the inner, which is wet with oil being indicated by a golden yellow colour – if not dyed mineral oil is in use – should not extend more than 25 to 50 mm form the separator base.

If the wet band, on examination, extends from the base to the top (flange) or almost to the top then the separator is saturated.

Determine cause of fault, rectify and re-use separator if not damaged, blocked or aged. When starting a compressor with a saturated separator an oil mist will be carried over (can be seen if blown to atmosphere) for a few minutes whilst the separator rids itself of excess oil. During this period the separator differential pressure will lower.

If the differential pressure does not reduce to 0.2 to 0.3 bar within 10 minutes whilst the compressor is on load then the separator should be replaced.

• Discoloured separator – dark amber / brown

Indicates oxidized mineral oil.

Determine compressor / compressor room / ventilation / pollutant fault and rectify, then change oil, oil filter and separator.

• Discoloured separator – grey to black

This indicates dirt retention and / or severe carbonization of oil. Check sealing and integrity of air filter and replace same. Check environmental conditions and rectify where possible. If compressor sounds different to the ear than normal when either n or off load or both then it indicates air-end and / or gear box wear and imminent failure. Compare monitored dB bearing readings to history / maximum allowed. Rectify cause of fault. Do not re-use separator.

• Non-discoloured separator with high differential pressure

Being normal at or beyond compressor manufacturer’s recommended change interval; this may be as low as 3000 hours for hot running compressors with small (mineral) oil fill. For cool running compressors or those with a large (mineral) oil fill, this may be 6000 to 8000 hours.

For the many reasons of high differential pressure prior to normal expected life refer to Section 1.0 above. Fine dust particles and extended molecular strings causing blockage do not generally discolour the outer filter media.

• Collapsed separator – no discolouration

Determine cause for high differential pressure which leads to a separator collapsing; compressor mechanical fault – minimum pressure valve or other cause, operational fault – opening or closing too rapidly of discharge air valve. Determine mechanical or operational fault and rectify.

• Collapsed separator – limited discolouration

Determine cause for high differential pressure which leads to a separator collapsing. Possible causes: build up of shellac, dirt or other particles, mixed oils.

• Collapsed separator – grey to black

Determine cause for high differential pressure which leads to a separator collapsing. Possible causes: incorrect oil, sludge formation, dirt, damaged or poor fit of air filter.

• Collapsed separator – black with carbon deposit

Either implosion or explosion; Study soot colour and grain: soot fined grained and grayish indicated an explosion and usually accompanied by mechanical damage to components between and inclusive of the air-end housing and separator tank, soot course grained and blackish indicates a flash fire. Determine cause, repair / overhaul compressor, change separator, air and oil filter and oil.

Features

• Low pressure drop and energy saving
• High quality filtration media
• Low oil consumption
• Reliable and stable
• Compact design
• Long life span

AIR OIL SEPARATOR

Qingdao Futai, Air Compressor Filter Manufacturer in China.