INDUSTRIAL CASE|METALLURGY|COMPRESSOR EQUIPMENT
REPORT OF KGGMK “KRIVOROZHSTAL” · OXYGEN PRODUCTION
Turbocompressor K-500: less electricity with no unit shutdown
PRODUCTXADO revitalizantsXADO technology · treatment under normal operating duty
TEST OBJECTTurbocompressor K-500ser. No. 9828 · electric motor, gearbox, bearing supports No. 1–9
DOCUMENT TYPEReport of the plant commission
approved by the works management
approved by the works management
Key results
↓6.1%
power drawn by the electric motor at idle, 2682.5 → 2518.0 kWh
↓4.8%
stator current of the electric motor at idle, 250 → 238 A
| UNIT ASSEMBLY | TREATMENT AND RUNNING TIME | WHAT WAS MEASURED |
|---|---|---|
| Turbocompressor K-500, ser. No. 9828 | Treated 25–27.12.2002 without taking out of service and without disassembly | Stator and rotor current, phase currents, power draw |
| Drive gearbox | Treated as part of the unit; check measurements after 435 and 890 h | Vibration of bearing supports No. 4–7 |
| Electric motor | Treated as part of the unit; check measurements after 435 and 888 h | Vibration of bearing supports No. 8–9, phase currents |
Idle duty (P = 0.8 atm) — electrical parameters
| PARAMETER | BEFORE TREATMENT | AFTER 435 H | AFTER 888 H |
|---|---|---|---|
| Power drawn per 1 hour | 2682.5 kWh | 2518.0 | 2518.0 |
| Stator current | 250 A | 238 | — |
| Rotor current | 200 A | 200 | 200 |
| Phase A current | 246.4 A | 244.0 | 248.0 |
| Phase B current | 249.6 A | 240.0 | 225.6 |
| Phase C current | 260.8 A | 237.6 | 225.6 |
Phase currents were measured with a VAF-85 instrument at a transformation ratio of 80, power — by the in-service meter. According to the conclusions of the report, the average current at idle dropped by 4.6 %.
Conclusions of the commission
The commission of KGGMK “Krivorozhstal” recorded: 1. As a result of the treatment of turbocompressor K-500 (ser. No. 9828) by the XADO technology, the current in idle duty decreased on average by 4.6 %, the power drawn by the electric motor at idle decreased by 164.5 kW per hour (6.1 %), which makes it possible to obtain savings amounting to 15500 UAH per month and to fully recoup the cost of the restorative repair of the turbocompressor carried out by the XADO technology. 2. The insignificant decrease (and on some supports an increase) of the vibration level after the turbocompressor had run 435 hours is explained by the fact that during the treatment period (after 360 hours of operation) an emergency shutdown was carried out because of a false tripping of the rotor axial shift protection, together with disassembly of the thrust bearing assembly for the purpose of inspection.
The results relate to turbocompressor K-500 (ser. No. 9828) of the oxygen production facility of KGGMK “Krivorozhstal” and to idle duty at a pressure of 0.8 atm; on other equipment and in other duties the figures may differ. The original report is published in full and available for download.
Current equivalent
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
How such units are treated: