What are the common problems of oil purifier？

Oil purifiers, including transformer oil purifiers and lubricating oil purifiers, are essential equipment for maintaining the cleanliness and functionality of oils in various industrial applications. However, like any machinery, oil purifiers can encounter issues that affect their performance, efficiency, and longevity. Here are some of the common problems of oil purifiers, along with potential causes and solutions:

1. Insufficient Purification Efficiency

Problem: The purifier fails to clean the oil effectively, leaving contaminants such as water, sludge, or solid particles in the oil.

• Causes:
  • Clogged Filters: Over time, filters can become clogged with contaminants, reducing their ability to remove impurities from the oil.
  • Wrong Purification Method: Using the wrong filtration or purification method for the type of contaminants (e.g., centrifugal filtration for water removal) can result in poor performance.
  • Overload: Purifiers running beyond their rated capacity can cause poor filtration and insufficient separation.
• Solutions:
  • Regularly ｒｅｐｌａｃｅ or clean filters.
  • Choose the right purification technology (e.g., centrifugal, vacuum, clay filtration) based on the contaminants.
  • Ensure that the purifier operates within its designed flow rate and capacity.

2. Oil Leakage

Problem: Oil leaks from various parts of the purifier, leading to oil wastage and environmental hazards.

• Causes:
  • Damaged Seals: Seals or gaskets can wear out over time, causing leaks around the joints.
  • Loose Connections: Bolts, screws, or connections may become loose, leading to leaks.
  • Corrosion: Corrosion of metal parts, especially in harsh environments, can create holes or cracks, resulting in leaks.
• Solutions:
  • Regularly inspect and ｒｅｐｌａｃｅ seals, gaskets, and O-rings.
  • Tighten connections to prevent leaks.
  • Use corrosion-resistant materials or coatings to protect parts from corrosion.

3. Excessive Noise or Vibration

Problem: The oil purifier produces excessive noise or vibration during operation, which could indicate malfunctioning components.

• Causes:
  • Unbalanced Components: An unbalanced purifier bowl or rotor can cause vibrations.
  • Damaged Bearings or Motors: Worn-out bearings or malfunctioning motors can lead to noise and vibration.
  • Improper Installation: If the purifier isn’t correctly installed or aligned, it may vibrate excessively.
• Solutions:
  • Inspect and balance the centrifuge or rotor.
  • Check and ｒｅｐｌａｃｅ bearings or motors if needed.
  • Ensure proper installation and alignment of the equipment.

4. High Power Consumption

Problem: The oil purifier consumes more power than normal, which can be costly and may indicate inefficiencies.

• Causes:
  • Clogged Filters: When filters are clogged, the pump or motor must work harder to push the oil through, increasing power consumption.
  • Faulty Motors: Malfunctioning or underperforming motors can result in higher energy consumption.
  • High Contaminant Load: A purifier operating with oil that has a very high level of contaminants can cause it to work harder than usual.
• Solutions:
  • Clean or ｒｅｐｌａｃｅ filters regularly.
  • Check and repair or ｒｅｐｌａｃｅ motors.
  • Maintain oil cleanliness and address contamination problems early.

5. Inconsistent Oil Flow or Low Flow Rate

Problem: Oil is not flowing through the purifier at the proper rate, which can delay the purification process.

• Causes:
  • Clogged Filters: Filters that are blocked with contaminants can restrict the oil flow.
  • Pump Issues: A faulty inlet pump can result in low flow rates.
  • Air Blockages or Leaks: Air pockets in the system or leaks in pipes can cause inconsistent oil flow.
• Solutions:
  • Regularly check and clean filters.
  • Inspect and repair the inlet pump or any related components.
  • Ensure all pipes are sealed properly to prevent air leaks and blockages.

6. Failure to Remove Water

Problem: The purifier is unable to remove water from the oil, leaving it contaminated and affecting the oil’s insulating properties.

• Causes:
  • Inefficient Water Separation: The centrifugal separator may not be effective in separating water due to design issues or excessive water content in the oil.
  • Insufficient Vacuum: In vacuum dehydration systems, a failure to maintain proper vacuum pressure can result in poor water removal.
  • Clogged or Improperly Set Skimmer: If the water removal mechanism (e.g., skimmer) is clogged or misadjusted, water will not be properly separated.
• Solutions:
  • Ensure the centrifugal separator is in good condition and is designed to handle the water content in the oil.
  • Check the vacuum pump and seals to ensure the system maintains proper vacuum pressure.
  • Adjust or clean the skimmer and ensure it operates as intended.

7. Overheating of Oil Purifier

Problem: The oil purifier becomes too hot during operation, which could damage components and reduce its lifespan.

• Causes:
  • Overloaded System: Operating the purifier beyond its rated capacity can cause overheating due to excessive friction or workload on components.
  • Inadequate Cooling: If the cooling system (e.g., heat exchangers or fans) is not functioning properly, the purifier may overheat.
  • Blocked Cooling Circuits: Dirt or debris in the cooling circuits can impede heat dissipation.
• Solutions:
  • Ensure the purifier is not overloaded and operates within its design limits.
  • Inspect and clean the cooling system to maintain efficient heat dissipation.
  • Check for blocked air intakes or cooling pathways.

8. Contaminant Build-Up in Sludge Discharge

Problem: The sludge chamber or waste collection system becomes too full or clogged, leading to poor oil filtration.

• Causes:
  • Infrequent Maintenance: Sludge buildup can occur if the discharge system is not regularly emptied or cleaned.
  • Excessive Contamination: High levels of contaminants in the oil can lead to rapid accumulation of sludge.
  • Clogged Drainage: Blockages in the discharge pipes can prevent sludge from being effectively removed.
• Solutions:
  • Perform regular maintenance to empty and clean the sludge discharge chambers.
  • Monitor oil contamination levels and address issues early to prevent excessive sludge accumulation.
  • Ensure that drainage systems are clear and functioning properly.

9. Inadequate Pressure or Suction

Problem: The purifier fails to maintain adequate pressure, leading to poor filtration or stoppages in the process.

• Causes:
  • Damaged or Worn-Out Pump: A malfunctioning pump can result in insufficient pressure or suction.
  • Clogged Filters: Filters that are too dirty can cause a ｄｒｏｐ in pressure.
  • Air Leaks: Leaks in the suction or discharge lines can disrupt pressure balance and cause operational problems.
• Solutions:
  • Inspect and repair the pump, if necessary.
  • Regularly clean or ｒｅｐｌａｃｅ filters to ensure they are not causing pressure drops.
  • Check for air leaks in the system and seal any identified leaks.

10. Alarm or Control System Malfunctions

Problem: The control panel or alarm system fails to function correctly, leading to unnoticed malfunctions or process errors.

• Causes:
  • Sensor Failures: Faulty sensors can provide inaccurate readings, triggering incorrect alarms or failing to notify operators about problems.
  • Wiring or Electrical Issues: Loose or damaged wiring can cause communication failures between the control system and the purifier.
  • Software Glitches: Issues with the software or control system can lead to malfunctioning alarms or failure to trigger automatic shutoffs.
• Solutions:
  • Regularly calibrate and test sensors for accuracy.
  • Inspect and repair electrical wiring and connections.
  • ｕｐｄａｔｅ or troubleshoot software to ensure proper operation.

Summary of Common Oil Purifier Problems and Solutions: