INDUSTRIAL CASE STUDY|MINING · METALLURGY|COMPRESSOR · ELECTRIC DRIVE
KAZZINC JSC REPORT · 1700 OPERATING HOURS IN SERVICE
4VM 10-120/9 compressor: less power to the drive, shaft geometry preserved
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
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: