Many factors can contribute to oil carryover in compressed air systems. However, there are approximately four or five items you may look at initially in a rotary screw compressor that won’t cost you much money. It’s critical to understand the sources of oil carryover in your compressed air system. Someone might be overfilling the oil reservoir, which could create oil carryover. If there is too much oil in the pool, it has no choice but to flow downstream until it reaches normal oil levels.
The temperature should be monitored if you see oil carryover in your compressed air systems. First, you must ensure that the water is not too cold. If a rotary screw compressor, for example, constantly runs at temperatures below 160 degrees Fahrenheit, it is operating too hard. Rotary screw compressors prefer to work at temperatures between 185 and 190 degrees Fahrenheit. If it is too cold, the system will not warm up sufficiently to allow the system to take the oil out on its own.
The final factor in evaluating is if all of these units have a separating filter. Again, whether it is a rotating vein or a rotary screw, the separator is set up such that air enters it, strikes the rear side of the wall, drops the oil out into the air, and continues to move. There is a scavenging line at the bottom of that separator housing. It returns to the air from the bottom of the separator housing. This is where all of the oil extracted from the air is dumped and subsequently recirculated. Sometimes the scavenge line becomes clogged, leaving the oil with nowhere to go, and it fills the separator and is pushed downstream.
Oil degradation might also be a concern. If the system goes three years without being serviced, the oil may deteriorate to the point where it causes carryover. It is not lubricating as it should, and it lacks the viscosity required. Finally, there are a few things to keep in mind. First, it is relatively straightforward to determine what causes the oil to transfer over most of the time.
What is the Concept of Oil Carry-Over?
Oil carryover occurred when oil used to lubricate compressors passes through the separator filter and into the discharge pipe. Because of the extensive usage of electronic components in compressed air systems, oil carryover problems have developed.
Excessive oil carryover may be costly, especially given the high cost of lubrication. Furthermore, carryover might cause other problems inside your rotary screw compressor. For example, the oil might combine with any dirt, corrosion, or water in your system. This sludge-like combination has a propensity to block the air compressor, necessitating repairs and maintenance.
What are the Main Causes of Oil Carry-Over?
There are five common causes of oil carryover in compressed air systems.
1. Excessive Oil in the Reservoir
If you or someone else has been overfilling the oil reservoir, this might result in oil carryover. When there is too much oil in a pool, it can only flow downstream. It will end once the oil levels have returned to normal. Until then, this will cause oil to enter the discharge pipe.
2. Low Temperature
If your rotary screw compressor is running too cold, oil carryover may occur. Ideally, the temperature of your compressed air systems should be kept between 185 and 190 degrees Fahrenheit. Anything below these temps is too cold and will hinder your system from sucking the oil out.
3. Faulty Separator Filter
The separator filter is critical to the correct operation of your compressed air system. For example, oil carryover might occur if your system has a malfunctioning separator filter. The separator filter aims to remove oil from compressed air and restore it to the lubricating system. Typically, the air that exits the separator tank contains two to three parts per million (PPM) of lubricant carryover. Therefore, if there is a significant increase in oil carryover, the separator filter should be changed.
4. Clogged Scavenge Line
The scavenge line is positioned at the bottom of the separator filter on your air compressor. It aims to recirculate the oil that the separator has extracted from the air. However, sometimes the scavenge line becomes clogged, leaving the oil with nowhere to go but downstream. If this occurs, there may be an excess of oil carryover.
5. Degradation of the Oil
The scavenge line is positioned at the bottom of the separator filter on your air compressor. It aims to recirculate the oil that the separator has extracted from the air. However, sometimes the scavenge line becomes clogged, leaving the oil with nowhere to go but downstream. If this occurs, there may be an excess of oil carryover. (compressed air systems)
How You Can Prevent the Oil Carry-Over
Regularly addressing the concerns above is the most efficient strategy to avoid oil carryover in your air compressor. Furthermore, only skilled staff should be in charge of maintaining your compressed air systems. This will eliminate human mistakes such as overfilling the reservoir.
Check your system’s temperature regularly to ensure it is between 185 and 190 degrees Fahrenheit. Check the separator filter and its scavenge line regularly to ensure that both are operational. Finally, you should replace the oil every year to avoid deteriorating and losing viscosity.