INDUSTRIAL CASE STUDY|MINING · ORE PROCESSING PLANT|COMPRESSORS · GEARBOXES · BEARINGS · LOCOMOTIVE

ACT ON THE RESULTS OF RESTORATIVE REPAIR · 19.05.2000

Compressors, gearboxes, bearings and a locomotive: restoration without disassembly

OJSC “Southern Mining and Processing Plant” (YuGOK) · approved by chief engineer N. I. Garmash; the act was signed by the plant’s chief mechanic, CJSC “Krivbassrudprom” and XADO LLC

Kryvyi Rih, Ukraine · contract No. 158 of 31.03.2000 · work 05.04–18.05.2000 · act dated 19.05.2000

PRODUCTXADO compoundstreatment using XADO technology® during normal operation, without disassembling the mechanisms

TREATED EQUIPMENTPlant workshop equipment305VP30/8 compressors · ROF-1, ROF-2, DF-1 and EKG-10 excavator gearboxes · induced-draught fan bearings · TM2UM-941 locomotive

DOCUMENT TYPECompany act
with signatures and seal

Key results

↑0.9-1.6mm

gearbox tooth thickness, wear before treatment at least 1.5 mm

↓37.5%

radial clearance of the induced-draught fan bearings

↓8.3-29.2%

current draw of the 305VP30/8 compressors

↓15%

locomotive fuel consumption at idle

EQUIPMENT	CONDITION AT THE START OF WORK	WHAT WAS MEASURED
305VP30/8 compressors, sinter plant	in operation, parameters recorded before treatment	filling time, current draw
ROF-1, ROF-2, DF-1 gearboxes	tooth working surface wear of at least 1.5 mm, scoring, pitting	tooth thickness, surface condition, no-load current
EKG-10 excavator gearbox	tooth wear, scoring, pitting	tooth thickness, surface condition
No. 3636 bearings of the induced-draught fan, DF-1	in operation, clearances recorded before treatment	radial and axial clearances
TM2UM-941 locomotive, UZhDT	in operation, parameters recorded before treatment	fuel consumption, oil pressure, compression

ROF-1, ROF-2, DF-1 and EKG-10 excavator gearboxes

PARAMETER	REPEAT MEASUREMENT RESULT
Tooth thickness of the mating gears	growth of 0.9-1.6 mm
Tooth working surface	scoring and pitting disappeared, the surface took on the look of a smooth ground finish; a build-up of the metal layer was recorded in the contact zone
No-load current draw	reduction of 3.5-5 %
Noise and vibration	reduction recorded by the commission

The layer builds up in the contact zone — exactly where the wear was: the coating regulates itself according to the load on the assembly.

No. 3636 bearings of the induced-draught fan, DF-1

PARAMETER	REPEAT MEASUREMENT RESULT
Radial clearance	reduction of 37.5 %
Axial clearance	reduction of 12.2 %

Narrowed clearances mean restored geometry of the raceways and rolling elements — that is, a deferred replacement of the bearing assembly.

305VP30/8 compressors, sinter plant

PARAMETER	REPEAT MEASUREMENT RESULT
Capacity (by filling time)	increase of 6.4-13.9 %
Current draw	reduction of 8.3-29.2 %

Filling time is a direct measure of a piston compressor’s capacity: more air in the same time and at a lower current.

Engine of the TM2UM-941 locomotive, UZhDT

PARAMETER	REPEAT MEASUREMENT RESULT
Compression across the cylinders	increase of 2-6 kgf/cm² together with levelling across all cylinders
Fuel consumption at idle	reduction of 15 %
Oil pressure	increase of 0.1 kgf/cm²

Higher compression levelled across the cylinders means restored sealing of the cylinder-piston group; hence the lower fuel consumption.

Findings of the OJSC «YuGOK» commission

The commission of OJSC «YuGOK» recorded: the positive results achieved testify to the effectiveness of applying XADO technology® to industrial equipment. The gear drives of the gearboxes, which before treatment had wear of at least 1.5 mm, scoring and pitting, took on the look of a smooth ground surface. Repair using XADO technology® is carried out during normal operation and requires no special equipment, premises or spare parts. XADO technology® makes it possible to: 1. extend the service life of equipment without replacing assemblies and parts; 2. extend the equipment overhaul interval; 3. cut equipment repair costs; 4. increase equipment output and reduce energy consumption; 5. extend oil service life, prevent wear and optimise clearances in mechanisms. The commission recommended introducing the technology at enterprises of the ore-mining industry.

The results relate to the listed equipment of the OJSC “YuGOK” workshops — the 305VP30/8 compressors, the gearboxes of the ore-processing plants and of the EKG-10 excavator, the induced-draught fan bearings and the TM2UM-941 locomotive; on other machinery and under other operating conditions the figures may differ. The original act with signatures and seal 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
Revitalizant gel for diesel enginesDiesel engines

How such units are treated: Compressor Reduction gearbox Bearings

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