INDUSTRIAL CASE|CHEMICAL INDUSTRY|REDUCER · GEAR DRIVE
IE A083PLANT REPORT ON EQUIPMENT TREATMENT WITH XADO TECHNOLOGY
Reducer R-102S: lower energy consumption with no production shutdown
Gearbox energy consumption decreased, a metal-ceramic layer appeared on the teeth. 5.2 % — reducer current draw, 230 → 218 A (2002).
PRODUCTXADO gel, 2700 mlapplied in 3 stages, under normal operating duty
TREATED UNITReducer R-102Stwo-stage, type TO31302-07-1-20x1500 · gear drives, intermediate shaft bearings, oil pump
DOCUMENT TYPEPlant report
with signatures and stampeight signatories from the customer and the contractor
with signatures and stampeight signatories from the customer and the contractor
Key result
↓5.2%
reducer current draw,230 → 218 A
| EQUIPMENT | DUTY AND RUNNING TIME | WHAT WAS MEASURED |
|---|---|---|
| Reducer R-102S, two-stage, drive for Urea-3 shop equipment | Load 70 %; check measurement after 400 h of running with the treatment | Current draw, oil pressure and temperature; opening of the housing |
Measurements before and after treatment, reducer load 70 %
| PARAMETER | BEFORE TREATMENT, 14.03.2002 | AFTER TREATMENT, 400 H, 2.04.2002 |
|---|---|---|
| Current draw under normal duty | 230 A | 218 A |
| Oil pressure | 1 atm | 3 atm |
| Oil temperature | 50 °C | 48 °C |
The report attributes the rise in oil pressure together with the drop in oil temperature to recovery of the reducer oil pump.
Conclusion of the plant commission
After the treatment the reducer cover was removed: in the area of direct tooth contact a “mirror” surface of a metal-ceramic layer had formed on the mating surfaces, and the thermal clearance of the intermediate shaft bearings had decreased. The commission of GPRUP “GPO Azot” recorded: “The positive results obtained demonstrate the effectiveness of applying XADO technology. Equipment recovery is carried out under normal operating duty and requires no special equipment.” XADO technology makes it possible to:
1. Reduce energy consumption.
2. Extend the service life of assemblies and parts.
3. Prevent wear and optimise clearances.
4. Reduce noise and vibration.
The plant recommended including scheduled preventive treatment of mechanisms by XADO technology in the budget for planned equipment repairs.
Current equivalent
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
- Revitalizant gel for hydraulic systemsHydraulics · pumps · hydraulic motors
How such units are treated:
About this result:
Limits of this report: The results refer to the two-stage reducer R-102S of the Urea-3 shop at GPRUP “GPO Azot” at 70 % load; on other assemblies and operating modes the figures may differ.