Ingersoll Rand UP6 scroll comp leaking oil?

[Beerhippie]

Howdy.

We have an Ingersoll Rand UP6-5 scroll comp. We've had it for a decade or so. I recently did the 2,000 hr. filter/coolant/oil replacement and lately I've noticed it is losing oil into the air reservoir. It has produced nearly oil-free air up until recently.

It also doesn't seem to be keeping up with high demands, like the canning line, requiring us to run the back-up compressor. We haven't had to do this since getting the IR.

I've checked the coolant/oil level as per the instructions. The level is correct and not overfilled.

Has anyone rebuilt one of these? Is it possible? If so, what do I need and where do I get it (already searched for rebuild kits--they're all for piston comps)?

 

[MacMcMacmac]

You probably need a new air oil separator, especially if it hasn't been done for 10 years. If it is plugging up, it may not be flowing air as it should. It may also have a rupture which could be the sudden source of oil in the air. It should be swapped out pretty regularly. The manual should give you the hours for it.

 

[Beerhippie]

You probably need a new air oil separator, especially if it hasn't been done for 10 years. If it is plugging up, it may not be flowing air as it should. It may also have a rupture which could be the sudden source of oil in the air. It should be swapped out pretty regularly. The manual should give you the hours for it.

That, unfortunately, was part of the 2,000 hour maintenance--which I just did--and have been doing every 2K hours or 2 years, whichever comes first. $500 per trip--these things are great, but not cheap.

 

[MacMcMacmac]

Your separator scavenge line may be plugged or obstructed. Is it running hot?

 

[Beerhippie]

Your separator scavenge line may be plugged or obstructed. Is it running hot?

I'm not sure if it's running hotter that usual. The comp is entirely enclosed in a cabinet, making it difficult to tell.

How would I go about checking/clearing the line?

Just to top it off, our IR refrigerated air dryer decided to die Monday evening, I bought it in March this year. Trying to get hold of anyone at IR to get it warrantied but not willing to wait hours on hold.

 

[MacMcMacmac]

You could pull the line from the separator tank, along with any tubing leading to the compressor element and check to see if it can pass air through it. Depending on how it is arranged inside the tank you may need to take the lid off of the separator tank and disconnect it from the inside. Many just drop down through the top of the tank to the bottom of the separator like a straw and can be pulled straight out.

 

[MacMcMacmac]

Was your compressor running over capacity when the oil carryover and the dryer failure occurred? They might all be related. Running below spec pressure can cause oil carryover. Excess air flow and heat might overload the dryer causing it to trip. Dryer offline results in reduced or no condensate removal. Other than that, you may have gotten a poorly made separator.

Might be a stuck thermal mixing valve causing an overheat condition, overwhelming the dryer, but I'd expect the compressor to trip first in that scenario.

You'll have to eliminate each factor one by one.

Is there a fault downstream causing a sudden increase in air demand?

 

[Beerhippie]

Was your compressor running over capacity when the oil carryover and the dryer failure occurred? They might all be related. Running below spec pressure can cause oil carryover. Excess air flow and heat might overload the dryer causing it to trip. Dryer offline results in reduced or no condensate removal. Other than that, you may have gotten a poorly made separator.

Might be a stuck thermal mixing valve causing an overheat condition, overwhelming the dryer, but I'd expect the compressor to trip first in that scenario.

You'll have to eliminate each factor one by one.

Is there a fault downstream causing a sudden increase in air demand?

The air dryer is a separate device and problem. Comp for the dryer appears to be frozen--it pulls 2 Ohms across the plug.

I'll have to look into the IR compressor this weekend when it's not in use.

It ran beautifully for at least ten years before developing the oil problem and difficulty keeping up with demand. It now has about 12K hours on the clock.

 

[American Locomotive]

FWIW: It's a rotary, not scroll compressor. Two different technologies.

I would expect a screw compressor to go well more than 12,000 hours without any major issues. I don't think a worn air end would cause it to pass more oil, since the same amount of oil is injected into the screws all the time anyways. Something with the oil separating cartridge or main separation drum comes to mind immediately.

Also, have you simply tried doing a leak check on the facilities? A 5HP screw still isn't very much air, and it would only take a few leaky fittings to start consuming quite a large portion of your available air.

 

[Beerhippie]

FWIW: It's a rotary, not scroll compressor. Two different technologies.

I would expect a screw compressor to go well more than 12,000 hours without any major issues. I don't think a worn air end would cause it to pass more oil, since the same amount of oil is injected into the screws all the time anyways. Something with the oil separating cartridge or main separation drum comes to mind immediately.

Also, have you simply tried doing a leak check on the facilities? A 5HP screw still isn't very much air, and it would only take a few leaky fittings to start consuming quite a large portion of your available air.

Yeah, I got that wrong and I do know better.

I have run a leak check recently and fixed several problems. Some are known and pre-existing. The comp just runs some pneumatic controls--tappet valves--and the canning line.

Like I said, I'll have to wait for the weekend to do any work on the comp as it's in use for the canning today and tomorrow.

Thanks for the suggestions, all. It's sounding like less of a problem than I had thought.

 

[RTM]

Is there a fault downstream causing a sudden increase in air demand?

In my days in a SoCal brewery, we referred to this problem as the PACs, personal air conditioners. Operators on the floor would aim the air hose at their workstation, all day long.

Fixed it by taking out the air chiller?, sending warm air out to the floor, after we bought a boatload of fans.

Check your thermometer on the packaging line, especially those areas close to the pasteurization system.

 

[Beerhippie]

In my days in a SoCal brewery, we referred to this problem as the PACs, personal air conditioners. Operators on the floor would aim the air hose at their workstation, all day long.

Fixed it by taking out the air chiller?, sending warm air out to the floor, after we bought a boatload of fans.

Check your thermometer on the packaging line, especially those areas close to the pasteurization system.

Our operation is a little smaller--like five people on the floor right now. I'd know immediately if any hanky-panky like that was going on.

I've now wasted large parts of two days trying to get IR to warranty the air dryer I bought back in March this year. I'd have to say, there are probably better companies to buy from.