IE S013TEST REPORTS · OCTOBER 2005 — MARCH 2007
K-500 turbocompressors: less power draw and vibration without opening the unit
Energy consumption dropped at the same load, stator current fell, support vibration decreased. 2.7–3.8 % — power consumption under load, 2334–2998 → 2248–2918 kW; 2.2–3.8 % — stator current of the drive electric motor, 193–266 → 188–256 A; 19–56 % — vibration displacement of bearing supports No. 1-9, all three units (2005–2007).
with signatures and stamps
What repeated on all three units
| MACHINE | OPERATING TIME BEFORE CONTROL MEASUREMENT | REPORT DATE | WHAT WAS MEASURED |
|---|---|---|---|
| Machine No. 1, serial No. 86 | 817 h | 25.10.2005 | power, current, vibration at 18 points, oil condition |
| Machine No. 2, serial No. 2724 | 422 h | April 2006 | power, current, vibration at 16 points |
| Machine No. 3, serial No. 11371 | 655 h | 22.03.2007 | power, current, vibration at 16 points, oil temperature |
Power consumption by unit
| MACHINE | MODE | BEFORE, kW | AFTER, kW | CHANGE |
|---|---|---|---|---|
| Machine No. 1, serial No. 86 | under load | 2334 | 2248 | −3.7 % |
| Machine No. 1, serial No. 86 | idle | 586 | 547 | −6.7 % |
| Machine No. 2, serial No. 2724 | under load | 2576 | 2477 | −3.8 % |
| Machine No. 2, serial No. 2724 | idle | 723 | 662 | −8.4 % |
| Machine No. 3, serial No. 11371 | under load | 2998 | 2918 | −2.7 % |
| Machine No. 3, serial No. 11371 | idle | 1122 | 1036 | −7.7 % |
Power was recorded by the unit’s standard control system. The report conclusions state a reduction of 2.7–3.8 % under load and 6.7–8.4 % at idle.
Stator current of the drive electric motor, under-load mode
| MACHINE | BEFORE, A | AFTER, A | CHANGE |
|---|---|---|---|
| Machine No. 1, serial No. 86 | 193 | 188 | −2.6 % |
| Machine No. 2, serial No. 2724 | 230 | 225 | −2.2 % |
| Machine No. 3, serial No. 11371 | 266 | 256 | −3.8 % |
Current was taken by the same standard system and in the same mode as power — an independent confirmation of the result on the electrical side.
Vibration of the bearing supports
| MACHINE | MEASURING POINTS | TYPICAL REDUCTION | MAXIMUM |
|---|---|---|---|
| Machine No. 1, serial No. 86 | 18 | 14–61 % | 82 % |
| Machine No. 2, serial No. 2724 | 16 | 22–41 % | 62 % |
| Machine No. 3, serial No. 11371 | 16 | 18–56 % | 85 % |
SENDIG 911 vibrometer, vibration displacement of supports No. 1-9 — turbocompressor, gearbox and electric motor. Of the 50 points on the three units, 49 showed a reduction.
Conclusions of the plant reports
Current equivalent
- Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
- Revitalizant gel for gearboxesGearboxes · transmissions · gear drives
How such units are treated:
About this result:
Limits of this report: The results relate to the K-500 turbocompressor units of the air-blower station of JSC Zaporizhzhia Iron Ore Plant and to the operating modes recorded in the reports; on other machines and in other modes the figures may differ. The measurements were carried out by the personnel of the plant’s power shop using the standard monitoring system together with representatives of XADO LLC.