ORU-220 kV compressor and GAZ-31: worn units recovered performance without teardown

Razdanskaya TES CJSC, power unit No. 2 and the ORU-220 kV switchyard · joint commission of the plant and Armen-XADO · chief engineer A. S. Abraamyan

Kotayk marz, Armenia · treatment 01.02.2001 · measurements through 02.03.2001

PRODUCTXADO compoundsrepair gel · protective grease · restoring compound 125 ml · gel for the oil system

TEST OBJECTORU-220 kV compressor,
turning gear of power unit No. 2, GAZ-31 carbearings 2314 and 313 SEN-4B · bearings No. 3 and No. 4 and the compressor piston group · petrol engine, gearbox, reduction gears

DOCUMENT TYPEActs of the joint commission of
Razdanskaya TES CJSC and Armen-XADO

Key results

↑2.5×

compression in the GAZ-31 cylinders, 2.9-3.0 → 7.3-7.5 atm

↑11-31%

air pressure at the compressor gauges, 2.7-7.5 → 3.0-9.8 atm

↓17-31%

vibration of compressor bearings No. 3 and No. 4, 50-240 → 40-200 mkr

EQUIPMENT	CONDITION AT THE START OF TESTS	WHAT WAS MEASURED
Compressor No. 1, ORU-220 kV, three-stage piston type	Increased noise, thermal gap of the 1st-stage piston ring 1.6 mm, motor current 60 A	Vibration of bearings No. 3 and No. 4, air pressure by the gauges
Turning gear motor of power unit No. 2	Bearing 2314 — pitting, wear, run-out; bearing 313 SEN-4B — radial clearance 0.04, roughness and run-out	Condition of the bearings in service
GAZ-31 car, petrol engine	Compression 2.9-3.0 atm in all four cylinders	Compression after 1500 and 3000 km of mileage

Compressor No. 1, ORU-220 kV — bearing vibration

MEASUREMENT DIRECTION	BEARING No. 3, BEFORE → AFTER	BEARING No. 4, BEFORE → AFTER
Vertical	100 → 80	50 → 40
Transverse	240 → 200	210 → 200
Axial	130 → 90	130 → 90

Measured in three directions on each bearing after 208 h of operation; the vibration level is given in the units used in the act — «mkr».

Compressor No. 1, ORU-220 kV — air pressure

GAUGE	BEFORE TREATMENT	AFTER 208 H OF OPERATION
Gauge 1	2.7 atm	3.0 atm
Gauge 2	7.5 atm	9.8 atm

The compressor's standard gauges; the rise in air pressure follows from the restored sealing of the 1st-stage piston group.

GAZ-31 car — compression by cylinder, atm

CYLINDER	BEFORE TREATMENT	AFTER 1500 KM	AFTER 3000 KM
Cylinder 1	2.9	3.1	7.3
Cylinder 2	3.0	3.7	7.5
Cylinder 3	3.0	4.9	7.5
Cylinder 4	3.0	4.9	7.5

Compression grew with mileage: by 3000 km three cylinders out of four came to one and the same value — the engine started running evenly.

Commission conclusions

The joint commission of Razdanskaya TES CJSC and Armen-XADO recorded in the act of 02.03.2001: for bearing 313 SEN-4B of the turning gear motor of unit No. 2 — «the run-out and roughness have stopped; according to the operating personnel everything is normal, no deviations have been noticed»; for compressor No. 1 of the ORU-220 kV switchyard — a drop in the vibration of bearings No. 3 and No. 4 in all three measurement directions and a rise in air pressure on both gauges after 208 h of operation; for the GAZ-31 car — a rise in compression in all four cylinders, 2.9-3.0 → 7.3-7.5 atm over 3000 km of mileage. The act of 28.02.2001 additionally notes: «the noise, as observed by the operating personnel, is fairly reduced». The units were treated in a worn condition — with pitting, run-out, radial clearance and increased noise — without disassembly and without taking the equipment out of service.

The results relate to the equipment of Razdanskaya TES CJSC — the ORU-220 kV piston compressor, the bearings of the turning gear motor of power unit No. 2 and the GAZ-31 petrol engine; on other machines and duties the figures may differ. The treatment was performed by Armen-XADO, whose representatives were members of the commission. The originals of the acts of 01.02.2001, 28.02.2001 and 02.03.2001, with signatures and stamps, are published in full and available for download.

Current equivalent

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

How such units are treated: Bearings Compressor Electric motor

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