1. Causes of Lubricating Oil Emulsification
Water-related Causes:
The working environment is too humid, leading to too much moisture in the air intake. This water does not separate properly from the oil.
Air-related Causes:
Low air usage causes the compressor to run unloaded for long periods, resulting in low operating temperatures, which can cause oil emulsification.
Oil-related Causes:
Lubricating oil is used for too long, and its performance decreases.
Equipment-related Causes:
The gap in the piston rings is too large.
Too much water collects in the cooler, allowing water to enter the cylinder, causing oil emulsification. Regular water draining is necessary.
Blocked air filters cause the oil to operate at high pressure and high temperature, damaging the oil’s properties.
2. How to Tell if Lubricating Oil is Deteriorating
Visual Inspection:
After emulsification, the oil looks milky white or yellowish with small bubbles. The oil level rises, and there may be strange noises from the oil pump, unstable oil pressure, and temperature warnings.
Touch Test:
Good quality oil feels smooth with no roughness. If you feel friction, it’s time to replace the oil.
Flow Test:
Good oil flows smoothly and evenly. If the flow speed changes too much, the oil may be bad.
3. Dangers of Oil Emulsification in Air Compressors
Oil emulsification can cause the compressor to stop working, interrupting production. In serious cases, it can damage the compressor or even lead to accidents. In screw compressors, problems like bearing failure and rotor damage can happen due to emulsified oil.
4. How to Prevent and Deal with Oil Emulsification
Daily Maintenance:
Before starting the compressor each day, drain the water from the oil tank. Open the drain valve, release the water until you see oil, then close the valve. This is especially important for companies with low air usage or when the oil temperature doesn’t reach 80°C.
Oil Usage Cycle:
Lubricating oil should be replaced after about 2,000 hours of use, though this can vary based on working conditions.
Cleaning Process:
If oil emulsification happens due to too much moisture in the air, clean all parts that contact the emulsified oil, including the oil separator, oil filter, oil pump, and compressor.
Disassembly and Inspection:
If oil emulsification has gone on for a long time, leading to high temperatures and strange noises, disassemble the compressor, clean it, and check for worn parts before putting it back together.