INDUSTRIAL CASE|MINING · ORE PROCESSING PLANT|AIR COMPRESSOR
OJSC STOYLENSKY GOK · REPORT OF 21.01.2011
Compressor 4VM10-100/9: less power and vibration without unit teardown
PRODUCTXADO revitalizant compoundsfull treatment cycle of the compressor oil system
TREATED UNITReciprocating opposed-piston air compressor 4VM10-100/9serial no. 56 · compressor station of the plant
DOCUMENT TYPECompany report
with signatures and seal
with signatures and seal
Key results
↓3.0%
power consumption in unloaded mode, 467.12 → 455.11 kW
↓26-37%
vibration displacement on housing and base, 9.0-83.3 → 6.4-64.2 µm
| EQUIPMENT | DUTY AND RUNNING TIME | WHAT WAS MEASURED |
|---|---|---|
| Reciprocating opposed-piston air compressor 4VM10-100/9, serial no. 56 | Regular service; “after” measurements taken after 677 h of operation from the start of treatment | Power consumption, oil pressure and temperature, vibration at six control points |
Compressor operating parameters
| PARAMETER | BEFORE TREATMENT | AFTER TREATMENT | CHANGE |
|---|---|---|---|
| Power consumption, unloaded mode | 467.12 kW | 455.11 kW | −12.01 kW |
| Oil pressure in the lubrication system | 3.6 kgf/cm² | 3.6 kgf/cm² | no change |
| Oil temperature | 52.4 °C | 52.3 °C | −0.1 °C |
Measured with an electronic electricity meter at a rotor current of 220 A, 132 h after the scheduled oil change. According to the report’s conclusions, the average reduction is 3.0 %.
Vibration at control points: housing (No. 1–No. 4) and base (No. 5–No. 6)
| POINT | DIRECTION | VIBRATION ACCELERATION, m/s² | VIBRATION VELOCITY, mm/s | VIBRATION DISPLACEMENT, µm |
|---|---|---|---|---|
| No. 1 | vertical | 4.21 → 2.49 | 1.81 → 1.00 | 9.00 → 6.41 |
| No. 1 | horizontal | 4.92 → 4.17 | 4.80 → 3.22 | 83.3 → 64.2 |
| No. 1 | axial | 3.55 → 3.20 | 1.87 → 0.91 | 15.9 → 8.47 |
| No. 2 | vertical | 2.65 → 1.77 | 1.75 → 0.94 | 9.54 → 6.75 |
| No. 2 | horizontal | 4.81 → 3.21 | 1.38 → 2.79 | 60.7 → 45.5 |
| No. 2 | axial | 4.73 → 2.18 | 1.77 → 0.907 | 13.1 → 8.67 |
| No. 3 | vertical | 4.17 → 2.53 | 2.01 → 1.28 | 15.2 → 13.4 |
| No. 3 | horizontal | 5.89 → 4.52 | 3.56 → 2.77 | 78.2 → 55.9 |
| No. 4 | vertical | 4.12 → 2.08 | 1.96 → 1.03 | 16.6 → 11.2 |
| No. 4 | horizontal | 4.57 → 4.42 | 1.08 → 2.51 | 71.6 → 44.0 |
| No. 5 | vertical | 3.15 → 1.85 | 1.93 → 0.975 | 16.7 → 12.4 |
| No. 5 | horizontal | 3.93 → 2.15 | 3.07 → 2.18 | 65.8 → 42.6 |
| No. 6 | vertical | 3.29 → 1.17 | 1.63 → 0.586 | 11.50 → 7.19 |
| No. 6 | horizontal | 3.15 → 2.03 | 2.36 → 1.43 | 45.5 → 26.8 |
Vibrometer “Sendig – 911”. Vibration displacement decreased in all 14 measurements, vibration acceleration also in all 14.
Report conclusions
The commission of OJSC Stoylensky GOK, together with XADO specialists, recorded the following: as a result of a full treatment cycle using XADO technology on the reciprocating opposed-piston compressor 4VM10-100/9, serial no. 56, operated at the compressor station, power consumption in unloaded mode decreased by an average of 3.0 %. At most control points on the compressor housing the vibration level decreased, which indicates the formation of optimal thermal clearances in the cylinder-piston and crank-connecting rod assemblies of the compressor. Optimization of thermal clearances contributes to an increase in the compressor service life. The treatment was carried out from 22 December 2010 to 20 January 2011 on the running compressor, and repeat measurements were taken after 677 hours of operation.
The results apply to the reciprocating opposed-piston air compressor 4VM10-100/9 under the conditions of the compressor station of OJSC Stoylensky GOK; on other equipment and in other operating modes the figures may differ. The original report of 21.01.2011 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 cylinder restorationEngine cylinders, deep wear
How such units are treated: