4VM 10-120/9 compressor: less power to the drive, shaft geometry preserved

The drive drew less rotor current under the same load, oil pressure in the running gear rose. 4VM 10-120/9 compressor, no. 1700, Kazzinc JSC. Kazakhstan · 2002.

Kazzinc JSC, LGOK industrial complex, power shop · commission: LGOK chief power engineer V. A. Voronin (chairman), LGOK chief mechanical engineer V. S. Laptiev, power shop chief engineer S. V. Seliverstov · approved by N. V. Prokhorenko, deputy chief mechanical engineer of Kazzinc JSC

Leninogorsk, Kazakhstan · treatment 26.11.2001 · control measurements and report 21.05.2002

PRODUCTXADO compounds · Compressor Gelrunning gear — 100 tubes in four stages · cylinder-piston group — 20 tubes through the standard lubricator

TEST OBJECT4VM 10-120/9 reciprocating compressorserial no. 1700 · drive SKD2-16-44-10, 800 kW, 6000 V

DOCUMENT TYPECommission report of Kazzinc JSC
signed and stamped

Key results

↓14.3%

drive rotor current under load, 210 → 180 A

↑0.2kgf/cm²

oil pressure in the running gear, 4.0 → 4.2 kgf/cm²

ASSEMBLY	HOURS RUN AT TEST START	WHAT WAS MEASURED
Running gear: crank mechanism, Ø180 crankshaft, bearing shells, crosshead bush	over 40,000 operating hours since 1992, last overhaul — 2001	drive current, oil pressure, dimensions of journals and bearing shells
Cylinder-piston group	same machine, serial no. 1700	level of the ultrasonic component by compressor rows

Drive current and oil pressure: before treatment and after 1700 operating hours

PARAMETER	BEFORE TREATMENT	AFTER 1700 OPERATING HOURS	CHANGE
Drive rotor current, under load	210 A	180 A	−14.3 %
Drive rotor current, no load	180 A	170 A	−5.6 %
Drive stator current, under load	70 A	70 A	no change
Drive stator current, no load	44 A	44 A	no change
Oil pressure in the running gear lubrication system	4.0 kgf/cm²	4.2 kgf/cm²	+0.2 kgf/cm²

Readings of the drive's standard instruments. Motor nameplate: 800 kW, stator current 81 A, rotor current 260 A — the machine ran in an unchanged load mode.

Conclusion of the Kazzinc JSC commission

Following 1700 hours of compressor operation after treatment with XADO compounds, the commission recorded: 1. The level of mechanical losses in the cylinder-piston group and the crank mechanism decreased: at no load — 5.6 %, under load — 14.3 %, which correspondingly reduces energy consumption. 2. Wear-free operation of the crankshaft was ensured for 1700 operating hours under load. 3. Oil pressure increased by 0.2 kgf/cm². At the control opening of the running gear the report states: "The connecting-rod and main journals showed no change in geometric dimensions. Traces of a shiny coating"; it is separately noted that the compressor runs quieter and smoother, with a reduced vibration level in the area of row 2. The machine came to the treatment with over 40,000 operating hours run, and the entire result was obtained without disassembly, on the running unit.

The results refer to a 4VM 10-120/9 reciprocating compressor with an 800 kW synchronous drive under the industrial operating conditions of LGOK; on other machines and duty modes the figures may differ. The treatment was performed by the contractor W.F.G. Corporation LLP (XADO technologies), whose representatives sat on the commission alongside officials of Kazzinc JSC. The original report is published in full and available for download.

Current equivalent

Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
Revitalizant gel for cylinder restorationEngine cylinders, deep wear

How such units are treated: Compressor Cylinder-piston group

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