Air compressor 4M10-120/9 — Gorlovskiy Machine-Building Plant

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INDUSTRIAL CASE|MECHANICAL ENGINEERING|COMPRESSOR UNIT

REPORT ON MEASUREMENT OF OPERATING PARAMETERS · GORLOVSKIY MACHINE-BUILDING PLANT JSC

Compressor 4M10-120/9: less power draw and vibration even after an overhaul

Gorlovskiy Machine-Building Plant JSC, compressor section  ·  measurements: chief power engineer V. A. Pankov, head of the PSU section V. V. Moskovskiy, foreman of the compressor section A. I. Saltevskiy  ·  approved by: deputy chief engineer for new technology A. F. Medvedev

Gorlovka, Ukraine  ·  report dated 27.02.2006 · repeat measurements at 405 h of running time after the full treatment cycle

PRODUCTXADO revitalizantsfull treatment cycle of the compressor oil system, without disassembling the unit
TEST OBJECTReciprocating air compressor 4M10-120/9inv. No. 33007 · in service · had undergone a major overhaul before treatment began
DOCUMENT TYPEPlant report
signed by the commission and stamped

Key results

↓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
EQUIPMENTCONDITION AT THE START OF MEASUREMENTSWHAT WAS MEASURED
Air compressor 4M10-120/9, inv. No. 33007In service; a major overhaul of the compressor was carried out immediately before the treatmentPower draw, stator and rotor current, oil pressure and temperature, vibration at 5 points, noise at 4 stages

Power consumption and the compressor oil system

PARAMETERBEFOREAFTERCHANGE
Power draw under load648.0 kW609.0 kW−39.0 kW (−6 %)
Stator current62.0 A60.5 A−1.5 A (−2.4 %)
Rotor current240.0 A240.0 Ano change
Discharge air pressure6.0 kgf/cm²6.0 kgf/cm²no change
Oil pressure2.4 kgf/cm²2.5 kgf/cm²+0.1 kgf/cm²
Oil temperature62.0 °C60.0 °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 POINTVIBRATION ACCELERATION, m/s²VIBRATION VELOCITY, mm/sVIBRATION DISPLACEMENT, µm
No. 1 casing · vertical4.55 → 1.652.05 → 0.68422.4 → 7.62
No. 1 casing · horizontal7.54 → 4.426.55 → 3.44104.0 → 85.5
No. 1 casing · axial7.55 → 1.73.54 → 0.90724.5 → 13.2
No. 2 casing · vertical8.28 → 1.813.95 → 1.0745.7 → 31.5
No. 2 casing · horizontal8.45 → 4.897.35 → 3.43112.5 → 78.7
No. 2 casing · axial8.56 → 1.954.25 → 0.98541.5 → 9.39
No. 3 casing · vertical5.46 → 1.684.85 → 0.68639.2 → 8.13
No. 3 casing · horizontal9.52 → 5.427.38 → 3.55104.6 → 77.5
No. 3 casing · axial7.45 → 1.674.87 → 0.79182.4 → 9.85
No. 4 casing · vertical7.14 → 1.975.2 → 1.0975.8 → 10.9
No. 4 casing · horizontal8.47 → 5.176.28 → 3.42157.2 → 87.2
No. 4 casing · axial7.56 → 1.754.65 → 0.996112.8 → 17.9
No. 5 foundation · vertical4.38 → 1.123.35 → 0.86687.5 → 16.8
No. 5 foundation · horizontal7.85 → 1.394.25 → 0.69696.4 → 10.5
No. 5 foundation · axial6.55 → 2.944.08 → 2.0877.5 → 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 POINTBEFOREAFTERCHANGE
Point No. 1 · stage IV94.0 dBA91.0 dBA−3.0 dBA
Point No. 2 · stage III93.0 dBA90.0 dBA−3.0 dBA
Point No. 3 · stage I93.0 dBA90.5 dBA−2.5 dBA
Point No. 4 · stage II94.0 dBA91.0 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

INDICATORVALUE
Reduction in power draw39.0 kW
Compressor operating time fund (6 months per year)1584 h
Electricity saved per season61 776 kWh
Plant electricity tariff0.2644 UAH/kWh
Monetary saving per season16 334 UAH
Payback of the treatment under normal operationno 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

The commission of Gorlovskiy Machine-Building Plant JSC recorded: as a result of treating the compressor with XADO technology, the noise level decreased by 2-3 dBA, and the vibration level at all measurement points decreased on average by 2.7×. The substantial improvement of these operating parameters of compressor 4VM10-120/9 "even after the major overhaul carried out on this compressor before the treatment began indicates the formation of optimal clearances between parts, which in turn makes it possible to extend the service life until the next major overhaul by at least 2×". Repeat measurements after the full treatment cycle and a total running time of 405 hours established that the power draw at identical compressor operating modes decreased by 6 %, or by 39.0 kW. The payback of the treatment costs is no more than 3.5 months of compressor operation in normal service.

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). The original report with signatures and stamp is published in full and available for download.

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: Compressor

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