47701889001 Ingersoll Rand air filter element

Functional Analysis of Various Components of Screw Air Compressors

1. Function of Air Filter

The main task is to prevent dust and other impurities in the air from entering the air compressor system.

Filtration accuracy: 98% of 0.001mm particles filtered out, 99.5% of 0.002mm particles filtered out, 99.9% of 0.003mm and larger particles filtered out. 

2. Function of Oil Filter

Removes all wear-causing impurities and dust from the lubricating oil but does not separate the special additives added.

Filter paper accuracy: 50% of 0.008mm particles filtered out, *** of 0.010mm particles filtered out. Counterfeit filter paper has not undergone heated lubricating oil testing, has fewer folds, significantly reducing the filtration area, and the fold spacing is uneven.

Function of the bypass valve in the oil filter: Prevents oil shortage in the air compressor oil pipeline, which could burn out compressor components. If the intake air contains a lot of dust, after the lubricating oil has been used for a period, the filter paper becomes severely clogged, hindering oil flow. When the oil entering the oil filter reaches a certain pressure difference (cold start or filter blockage), the bypass valve in the filter opens to ensure sufficient oil flow. The bypass valve must open at the precise pressure difference; if the pressure difference is too small, the oil filter becomes ineffective, causing premature wear of components; if the pressure difference is too large, oil shortage occurs, leading to excessively high oil temperature and potential rotor damage.

Method for replacing the oil filter: Loosen the oil filler plug one turn to depressurize the system;

To avoid oil splashing, prepare an oil container, remove the oil filter; clean the oil filter base, apply oil to the new filter gasket, screw it onto the base, and tighten by hand; tighten the oil filler plug.

3. Working Principle of Oil-Gas Separator

(1) Function of Oil-Gas Separator: Mainly separates the lubricating oil from the oil-gas mixture in the air compressor; continues to remove lubricating oil微粒 from the compressed air. The oil-gas mixture enters the oil tank (composed of the oil-gas separator, minimum pressure valve, safety valve, and container housing) and undergoes three types of separation: centrifugal separation, gravity separation (oil is heavier than gas), and fiber separation. Separation process: The oil-gas mixture enters the oil tank tangentially along the outer wall of the oil-gas separator, where 80%–90% of the oil is separated (centrifugal separation). The remaining oil (10%–20%) adheres to the outer wall surface for separation (gravity separation). A small amount of oil enters the interior of the oil-gas separator (fiber separation) and is pressed back into the screw chamber via the oil return pipe.

(2) Conductive Gasket of Oil-Gas Separator: As air and oil pass through the glass fiber, static electricity is generated between the two separation layers. If both metal layers become charged, there is a risk of electrostatic discharge accompanied by sparks, which could cause an explosion of the oil-gas separator. The gasket is used to seal the oil-gas separator core and the air receiver, but this may lead to the accumulation of an electrostatic field between the separator core and the air receiver housing. High-quality oil-gas separator accessories ensure conductivity between the separator core and the air receiver housing. The metal components of the air compressor have good conductivity, ensuring all static electricity is promptly discharged, preventing spark generation.

(3) Adaptability of Oil-Gas Separator to Pressure Difference: The oil-gas separator is designed to withstand a maximum pressure difference of 0.5 MPa. If the filter core exceeds this承受 value, the lubricating oil cannot be separated, affecting the entire machine or causing complete damage to the separator core. For every additional 0.1 MPa pressure difference in the oil-gas separator core, the total motor energy consumption increases by 7%; excessively high pressure drop in the oil-gas separator can cause it to catch fire. Causes of excessively high pressure difference may include the following four points: clogging of the oil separator due to dirt, air backflow, significant internal pressure fluctuations, and counterfeit oil-gas separator cores.

(4) Electroplated Metal of Oil-Gas Separator to Prevent Corrosion: Depending on the surrounding environment (temperature and humidity) and the operating conditions of the air compressor, condensation may form inside the oil-gas separator. If the oil-gas separator is not electroplated, a corrosive layer may form, which damages the antioxidant properties of the air compressor oil, significantly reducing its service life and the oil's flash point.

(5) Measures to Extend the Service Life of the Oil-Gas Separator: Accumulated dust, residual oil, air pollutants, or wear can reduce the service life of the oil-gas separator. ① Timely replacement of air filters and oil filters, along with monitoring oil change intervals, can limit dust entering the air compressor oil. ② Use the correct, high-quality lubricating oil that is not affected by water.

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