IE A042REPORT ON MEASUREMENT OF OPERATING PARAMETERS · GORLOVSKIY MACHINE-BUILDING PLANT JSC
Compressor 4M10-120/9: less power draw and vibration even after an overhaul
Energy consumption decreased at the same operating mode, housing and foundation vibration dropped. 6 % — power draw under load, 648.0 → 609.0 kW; 2.4 % — stator current of the electric motor, 62.0 → 60.5 A; 52–79 % — vibration velocity at the measurement points, 2.05–7.38 → 0.684–3.55 mm/s (2006).
signed by the commission and stamped
Key results
| EQUIPMENT | CONDITION AT THE START OF MEASUREMENTS | WHAT WAS MEASURED |
|---|---|---|
| Air compressor 4M10-120/9, inv. No. 33007 | In service; a major overhaul of the compressor was carried out immediately before the treatment | Power draw, stator and rotor current, oil pressure and temperature, vibration at 5 points, noise at 4 stages |
Power consumption and the compressor oil system
| PARAMETER | BEFORE | AFTER | CHANGE |
|---|---|---|---|
| Power draw under load | 648.0 kW | 609.0 kW | −39.0 kW (−6 %) |
| Stator current | 62.0 A | 60.5 A | −1.5 A (−2.4 %) |
| Rotor current | 240.0 A | 240.0 A | no change |
| Discharge air pressure | 6.0 kgf/cm² | 6.0 kgf/cm² | no change |
| Oil pressure | 2.4 kgf/cm² | 2.5 kgf/cm² | +0.1 kgf/cm² |
| Oil temperature | 62.0 °C | 60.0 °C | −2.0 °C |
Standard instrumentation of the compressor unit; the “after” measurements were taken at 405 h of running time and in the same compressor operating mode.
Vibration at the compressor measurement points
| MEASUREMENT POINT | VIBRATION ACCELERATION, m/s² | VIBRATION VELOCITY, mm/s | VIBRATION DISPLACEMENT, µm |
|---|---|---|---|
| No. 1 casing · vertical | 4.55 → 1.65 | 2.05 → 0.684 | 22.4 → 7.62 |
| No. 1 casing · horizontal | 7.54 → 4.42 | 6.55 → 3.44 | 104.0 → 85.5 |
| No. 1 casing · axial | 7.55 → 1.7 | 3.54 → 0.907 | 24.5 → 13.2 |
| No. 2 casing · vertical | 8.28 → 1.81 | 3.95 → 1.07 | 45.7 → 31.5 |
| No. 2 casing · horizontal | 8.45 → 4.89 | 7.35 → 3.43 | 112.5 → 78.7 |
| No. 2 casing · axial | 8.56 → 1.95 | 4.25 → 0.985 | 41.5 → 9.39 |
| No. 3 casing · vertical | 5.46 → 1.68 | 4.85 → 0.686 | 39.2 → 8.13 |
| No. 3 casing · horizontal | 9.52 → 5.42 | 7.38 → 3.55 | 104.6 → 77.5 |
| No. 3 casing · axial | 7.45 → 1.67 | 4.87 → 0.791 | 82.4 → 9.85 |
| No. 4 casing · vertical | 7.14 → 1.97 | 5.2 → 1.09 | 75.8 → 10.9 |
| No. 4 casing · horizontal | 8.47 → 5.17 | 6.28 → 3.42 | 157.2 → 87.2 |
| No. 4 casing · axial | 7.56 → 1.75 | 4.65 → 0.996 | 112.8 → 17.9 |
| No. 5 foundation · vertical | 4.38 → 1.12 | 3.35 → 0.866 | 87.5 → 16.8 |
| No. 5 foundation · horizontal | 7.85 → 1.39 | 4.25 → 0.696 | 96.4 → 10.5 |
| No. 5 foundation · axial | 6.55 → 2.94 | 4.08 → 2.08 | 77.5 → 45.0 |
“Sendig-911” vibration meter: points No. 1-No. 4 on the compressor casing, No. 5 on the foundation. A reduction was obtained at all 15 points for all three quantities.
Noise level at the compressor stages
| MEASUREMENT POINT | BEFORE | AFTER | CHANGE |
|---|---|---|---|
| Point No. 1 · stage IV | 94.0 dBA | 91.0 dBA | −3.0 dBA |
| Point No. 2 · stage III | 93.0 dBA | 90.0 dBA | −3.0 dBA |
| Point No. 3 · stage I | 93.0 dBA | 90.5 dBA | −2.5 dBA |
| Point No. 4 · stage II | 94.0 dBA | 91.0 dBA | −3.0 dBA |
Sound level meter model “0024”, measurements taken at each of the four compressor stages.
Economic effect as calculated by the plant
| INDICATOR | VALUE |
|---|---|
| Reduction in power draw | 39.0 kW |
| Compressor operating time fund (6 months per year) | 1584 h |
| Electricity saved per season | 61 776 kWh |
| Plant electricity tariff | 0.2644 UAH/kWh |
| Monetary saving per season | 16 334 UAH |
| Payback of the treatment under normal operation | no more than 3.5 months |
The calculation was made by the plant using its own tariff and the compressor operating time fund; Ukrainian prices of 2006.
Conclusions of the plant commission
Current equivalent
Revitalizant gel for compressors and bearings →
Piston, screw and centrifugal compressors; rolling and sliding bearings running in an oil bath; machine-tool spindle units and slideways.
How such units are treated:
About this result:
Limits of this report: The results relate to the reciprocating air compressor 4M10-120/9 under the operating conditions of Gorlovskiy Machine-Building Plant JSC; on other equipment and in other operating modes the figures may differ. The economic calculation is given according to the tariff and the operating time fund of the plant (Ukraine, 2006).