INDUSTRIAL CASE STUDY|MINING · RAIL TRANSPORT|LOCOMOTIVE COMPRESSORS
MEASUREMENT PROTOCOLS No. 1–4 · DEPARTMENT EXPLANATORY MEMO
KT-6 locomotive compressors: harder cylinders, lower current and oil use — no disassembly
PRODUCTXADO revitalizant repair gelsgel for cylinders · gel for compressors and bearings
TREATED EQUIPMENTKT-6 compressors5 compressors of OPE-1 traction units No. 294, 317, 343, 344
DOCUMENT TYPEMeasurement protocols No. 1–4
and explanatory memo of the railway department
and explanatory memo of the railway department
Key results
↑6-25%
cylinder wall hardness, 269-278 → 292-347 HB
↓18.4%
compressor current draw, 19 → 15.5 A
| TRACTION UNIT / COMPRESSOR | CONDITION AND TREATMENT SITE | WHAT WAS MEASURED |
|---|---|---|
| OPE-1 No. 344, KT6 No. 1 | In service, 2 years 5 months of operation; treated on the locomotive | Output, oil consumption |
| OPE-1 No. 344, KT6 No. 2 | In service, 2 years 5 months of operation; treated on the locomotive | Output, oil consumption |
| OPE-1 No. 294, KT6 No. 2 | After overhaul; treated on the depot run-in bench | Cylinder wall hardness, current draw |
| OPE-1 No. 343, KT6 No. 2 | After overhaul; treated on the depot run-in bench | Output, oil consumption |
| OPE-1 No. 317, KT6 No. 1 | After overhaul; treated on the depot run-in bench | Output, oil consumption |
Cylinder wall hardness and current draw — compressor of OPE-1 No. 294
| PARAMETER | BEFORE TREATMENT | AFTER 2 H RUN-IN | CHANGE |
|---|---|---|---|
| Stage 1 cylinder No. 1, previously in service | 269 HB · 23.1 HRC | 297 HB · 29.3 HRC | +28 HB · +6.2 HRC |
| Stage 1 cylinder No. 2, new | 275 HB · 24.7 HRC | 292 HB · 30.3 HRC | +17 HB · +5.6 HRC |
| Stage 2 cylinder, new | 278 HB · 26.5 HRC | 347 HB · 31.0 HRC | +69 HB · +4.5 HRC |
| Current draw on the bench | 19 A | 15.5 A | −3.5 A |
Three hardness measurements per cylinder: before treatment, after 30 minutes and after 2 hours of run-in. The protocol sums the increase as 5-6 HRC units.
Compressor output on locomotives, air system fill time
| TRACTION UNIT / COMPRESSOR | AFTER TREATMENTS No. 1 / No. 2 / No. 3 | AFTER 3 DAYS | AFTER 20 DAYS |
|---|---|---|---|
| OPE-1 No. 344, KT6 No. 1 | 70 / 60 / 51 s | 45 s | 44 s |
| OPE-1 No. 344, KT6 No. 2 | 70 / 65 / 54 s | 48 s | 44 s |
| OPE-1 No. 343, KT6 No. 2 | 55 s (after treatment No. 3) | 51 s | 39 s |
| OPE-1 No. 317, KT6 No. 1 | 58 s (after treatment No. 3) | 51 s | 44 s |
Air system fill time as per the air brake instructions; a shorter time means higher output. Measured on locomotives in service.
Conclusion of the railway transport department
The explanatory memo from the plant's railway transport department to the chief mechanic states: 1. Compressor output increased. 2. Oil consumption decreased and, accordingly, oil carry-over from the compressor crankcase into the pneumatic lines of the locomotive and the dump cars was eliminated. 3. Cylinder wall hardness increased, which will extend their service life. 4. Electricity consumption for compressed air generation decreased. Compressor oil consumption on traction unit No. 344 fell 2× and 2.5× on the two compressors; on units No. 343 and No. 317, after 20 days of operation the oil level in the crankcase remained practically unchanged. The department notes: the treatment requires no removal or disassembly of the compressor and is carried out during scheduled breaks, while the cost per compressor does not exceed 1400 roubles at 2002 prices.
The results relate to KT-6 locomotive compressors of OPE-1 traction units used in the industrial rail transport of a mining and processing plant; with other units and operating modes the figures may differ. Measurement protocols No. 1–4 and the explanatory memo signed by the responsible officials are 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
- Revitalizant gel for diesel enginesDiesel engines
How such units are treated: