INDUSTRIAL CASE|MECHANICAL ENGINEERING|COMPRESSORS · CRANK MECHANISM AND CYLINDER-PISTON GROUP

TECHNICAL REPORT OF 05.12.2003 WITH ECONOMIC EFFICIENCY CALCULATION

Compressor VP-20/8: lower current, faster charging, no shutdown, no teardown

KRAST JSC, Stavropol Truck Crane Plant · commission: chief engineer V. A. Yakhno, chief power engineer I. N. Selivanov · work performed by Revitalization Center LLC

Russia · work contract No. 16 of 20.11.2003 · works 20.11–05.12.2003 · report of 05.12.2003

PRODUCTXADO technologyMK treatment of the crank mechanism and cylinder-piston group — restoration of rubbing surfaces without disassembly

TEST OBJECTCompressor VP-20/8Serial No. 9949 · 29 years in service · receivers with a total volume of 27 m³

DOCUMENT TYPETechnical report
with economic efficiency calculation

Key results

↓33-37%

drive motor current at operating modes, 180-245 → 120-160 A

↓1.5min

time to fill the 27 m³ receivers to 6 kgf/cm², 7 → 5.5 min

↑11.4%

first-stage pressure at the operating mode, 1.75 → 1.95 kgf/cm²

EQUIPMENT	CONDITION AT START OF WORK	WHAT WAS MEASURED
Compressor VP-20/8, serial No. 9949	Built in 1974, 29 years in service; treated on site, without taking it out of operation	Drive motor current and stage pressures at five operating modes, time to fill the 27 m³ receivers to 6 kgf/cm², oil pressure in the crank mechanism lubrication system

Motor current and first-stage pressure by operating mode

2ND-STAGE PRESSURE, kgf/cm²	CURRENT BEFORE, A	CURRENT AFTER, A	CURRENT CHANGE	1ST-STAGE PRESSURE, kgf/cm²
6.0 — operating mode	245	160	−34.7 %	1.75 → 1.95
5.0	230	145	−37.0 %	1.65 → 1.8
4.0	205	130	−36.6 %	1.5 → 1.7
3.0	180	120	−33.3 %	1.4 → 1.55

First-stage pressure rose at every mode — a direct sign of reduced clearances in the cylinder-piston group and restored sealing.

Output and lubrication system

PARAMETER	BEFORE TREATMENT	AFTER TREATMENT
Time to fill the 27 m³ receivers to 6 kgf/cm²	7 min	5 min 30 s
Oil pressure in the crank mechanism lubrication system	2.9 kgf/cm²	2.9 kgf/cm²

According to the conclusion of the report, compressor output increased by 22 %; our measurement of the receiver filling time is 7 → 5.5 min.

Commission findings

The compressor had been running at the plant for 29 years, and the MK treatment of the crank mechanism and cylinder-piston group by XADO technology was performed while it stayed in operation — without stopping for repair, without disassembly and without replacing parts. The commission of KRAST JSC and Revitalization Center LLC recorded: “The measurements established that the parameters characterizing the operation of the compressor differ for the better.” Conclusions of the report: 1. As a result of the MK treatment of the crank mechanism and cylinder-piston group, the rubbing metal parts were restored and friction between them was significantly reduced, which made it possible to increase compressor output by 22 % while simultaneously reducing power consumption by 35 %. 2. The results obtained confirm the expediency of performing MK treatment on equipment units.

The results relate to the VP-20/8 piston compressor (serial No. 9949) and to its normal operating modes; on other equipment and under other conditions the figures may differ. The treatment was performed by Revitalization Center LLC, which also prepared the economic efficiency calculation attached to the report. The original technical report of 05.12.2003 with signatures and stamps 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: Compressor Cylinder-piston group

← Full catalogue