INDUSTRIAL CASE|POWER GENERATION|PUMPS · BEARINGS
ZMIIVSKA TPP TEST REPORT · TURBINE SHOP
NTS-7G district heating pump: lower current draw and bearing vibration, no teardown
PRODUCTXADO “Restorative” greaserevitalizant for bearing units
TEST OBJECTNTS-7G district heating pumpbearing units of the pump and its drive motor
DOCUMENT TYPEZmiivska TPP test report
signatures, seal
signatures, seal
Key results
↓11.6%
motor current draw under load, 25.8 → 22.8 A
↓23-66%
vibration acceleration of pump and motor bearing housings, 12.9-224 → 9.05-56.9 m/s²
| MACHINE | CONDITION AT START OF TESTING | WHAT WAS MEASURED |
|---|---|---|
| NTS-7G district heating pump | In service; bearings No. 3086313 and No. 6313, radial clearance 0.19 and 0.08 mm | Vibration of the front and rear bearing housings — vertical and horizontal |
| Pump drive motor | In service; bearings No. 322 and No. 2322, radial clearance 0.18 and 0.13 mm | Current draw of phases A, B, C; vibration of the front bearing housing |
Motor current draw
| MODE | BEFORE TREATMENT | AFTER 515 H | CHANGE |
|---|---|---|---|
| Under load — operating mode | 25.8 A | 22.8 A | −11.6 % |
| No load | 20.4 A | 16.8 A | −17.6 % |
Current is identical across all three phases A, B, C. Under load: pump inlet pressure 2.4 kgf/cm², outlet pressure 8 kgf/cm².
Vibration of the pump and motor bearing housings
| MEASUREMENT POINT | VIBRATION ACCELERATION, m/s² | VIBRATION VELOCITY, mm/s | VIBRATION DISPLACEMENT, µm |
|---|---|---|---|
| Pump, front housing, vertical | 12.9 → 18.3 | 1.46 → 0.904 | 18.9 → 9.97 |
| Pump, front housing, horizontal | 13.0 → 10.0 | 0.893 → 0.518 | 9.95 → 4.53 |
| Pump, rear housing, vertical | 27.0 → 17.3 | 1.00 → 0.763 | 15.0 → 13.2 |
| Pump, rear housing, horizontal | 13.9 → 9.05 | 0.865 → 0.539 | 8.03 → 6.45 |
| Motor, front housing, vertical | 224.0 → 47.9 | 0.931 → 0.804 | 12.7 → 12.4 |
| Motor, front housing, horizontal | 166.0 → 56.9 | 1.30 → 1.48 | 21.5 → 22.6 |
Six control points on the bearing housings; for each of the three parameters vibration decreased at five points out of six.
Findings of the Zmiivska TPP commission
The commission of Zmiivska TPP recorded: The vibration level of the pump and motor bearing housings decreased in all measurement directions by 2 % up to 4.5× at individual points. The current drawn by the motor with the pump under load decreased by 11.6 %, and with the pump fully unloaded — by 17.6 %. At a power consumption under load of 285 kW, the hourly saving is about 31 kW, or 744 kW per day in round-the-clock operation — that is 104 UAH per day and about 3124 UAH per month. The cost of treating the pump set with XADO technology is 225 UAH, with a payback period of no more than three days. The expected annual economic effect is at least 18,500 UAH, allowing for preventive maintenance and process downtime.
The results relate to the NTS-7G district heating pump with its drive motor at Zmiivska TPP; on other equipment and in other operating modes the figures may differ. The economic calculation is given in the report itself, at the plant tariff of 0.14 UAH per 1 kW·h for 2005. The original report 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 hydraulic systemsHydraulics · pumps · hydraulic motors
How such units are treated: