REPORT ON LOSS OF COMPRESSOR OIL FROM PRIMARY OIL SEPERATOR

PROBLEM:
Reduction of oil level in primary oil separator of C 104 A3 found.

PROBLEM FACED:
The problems faced due to loss of oil from primary oil separator are as follows.
1. Oil manifold temperature high.
2. Discharge temperature high.
3. Discharge pressure high.
4. Motor amps increasing due to improper lubrication.

PROBLEM DESCRIPTION:
 Initially during the oil change of C 104 A3 compressor on ,
 Level of oil in % :
 Level of oil as indicated by level troll :
 The amount of oil added in litres :
 The oil level was high, in turn caused rise in oil temperature, so in order to optimize the oil level
it was reduced.
 Level of oil in % :
 Level of oil as indicated by level troll :
 The amount of oil removed in litres :
 There was persistent reduction of oil level in primary oil separator.
 A sudden decrease in level was observed after the draining of economizer.

PROBLEM ANALYSIS:

S.NO ACTION OBSERVATION FINDING

1 The drain line was
depressurized and opened to
check availability of oil.
2 The suction line and the
strainer in the suction were
checked
3 The secondary oil separator
was drained
4 Economizer outlet was
checked
5 Buffer tank T 402 drain was
checked
Initially small quantity of oil was
found , after which a continuous
flow was observed
No trace of oil found
80 litres of oil found
No trace of oil found
Nearly 3.25 drums (700 litres
approx ) of Oil were collected.
Some valve in the drain of
HT oil circulation system is
passing
Too much oil carry over to
secondary oil separator (10
ppm by design)
Oil was carried over from
primary oil separator to
buffer tank through the oil
reclaimer.
POSSIBLE REASONS:

1. The HT compressor package drain valve is not holding well.

2. The valve passing causes the oil to drain form primary oil separator.
3. The drain line is pressurized up to 15 Kg/cm2 (i.e the compressor discharge).
4. The pressurized oil in the drain line moves in to the economizer, which has lower pressure.
5. Whenever the economizer is opened to oil reclaimer in order to reduce its level, the oil is
carried over from the oil reclaimer to the buffer tank through the common line connecting
tank T101B.
6. This is also the reason for increase in economizer level, when it is opened to drain.

RECOMMENDATIONS:

1. Valve passing to be found and attended immediately.

2. Level gauge in T 402 to be made functional.
3. Method to note down the secondary oil separator oil pressure to be found.
4. An SOP to be made for regular draining of T-402 water and possible contamination
5. Secondary oil separator to compressor suction tubing to be checked and % of opening to be
fixed, so that the oil is circulated within the compressor.