202VP-12/3 compressor: no teardown, no shutdown — faster charging, cooler air

OJSC Kupiansk Bread Plant: chief engineer O. E. Kolosovsky, chief mechanic A. V. Gromakov · XADO LLC: general director V. L. Zozulya, head of implementation department A. I. Vinnichenko

Kharkiv region, Ukraine · contract No. 22 dated 23.11.1999 · act signed 30.08.2000

PRODUCTXADO RVSrepair and restoration compound; introduced into the lubrication system while the compressor was running

TREATED UNIT202VP-12/3 reciprocating compressorcylinders and lubrication system (crankcase)

DOCUMENT TYPEBilateral act
with signatures and sealsOJSC Kupiansk Bread Plant and XADO LLC

Key results

↓45s

time to reach the working pressure of 3.2 kgf/cm², 4 min 40 s → 3 min 55 s

↓21-25%

discharge air temperature in both cylinders, 140-160 → 110-120 °C

EQUIPMENT	CONDITION AT THE START OF THE TRIAL	WHAT WAS MEASURED
202VP-12/3 reciprocating compressor	In service at the plant: pressure of 3.2 kgf/cm² was reached in 4 min 40 s, discharge air at 140-160 °C, elevated oil consumption	Time to reach working pressure, discharge air temperature in both cylinders, oil consumption in the crankcase

What changed on the compressor after treatment

PARAMETER	BEFORE TREATMENT	AFTER TREATMENT
Time to reach 3.2 kgf/cm²	4 min 40 s	3 min 55 s
Discharge air temperature, both cylinders	140-160 °C	110-120 °C, stable
Oil consumption in the crankcase	elevated	3× lower

The pressure is the same in both measurements — 3.2 kgf/cm²: what is compared is the time the compressor needs to reach it, that is, the capacity of the unit.

Findings of the commission

The treatment was carried out without disassembly and without stopping production: the compound was introduced into the lubrication system of the running compressor. The commission of OJSC Kupiansk Bread Plant and XADO LLC recorded that after treatment the compressor reaches 3.2 kgf/cm² in 3 min 55 s, whereas before treatment this took 4 min 40 s. The discharge air temperature in both cylinders fell from 140-160 °C to 110-120 °C and stabilised, and oil consumption in the crankcase decreased 3×. All three results point to one thing — the restored tightness of the cylinder-piston group: less blow-by means faster pressure build-up, weaker heating of the compressed air and less oil carry-over. In the conclusions of the act the commission recommended carrying out the same work on the next compressor of the enterprise.

The results refer to the 202VP-12/3 reciprocating compressor under the conditions of OJSC Kupiansk Bread Plant; on other units and duty cycles the figures may differ. RVS is an obsolete XADO designation for zero-generation compounds; the current product generation is revitalizants. The original act 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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