Screw compressors without an oil pump
The procedure describes the treatment of operable screw compressors with a lubrication system without an oil pump using XADO revitalizant gel for compressors and bearings (industrial), without shutdown or disassembly. The purpose is restorative repair and wear protection, with monitoring of vibration and power consumption before and after treatment.
Procedure for treating screw compressors with a lubrication system without an oil pump using XADO revitalizant compounds
What is treated
- Operable screw compressors having no parts with 100% wear or macromechanical damage
- Screw compressors with a lubrication system without an oil pump
- New screw compressors or those with initial wear (up to 10%) — treated in 5 stages at the same consumption rate
- It is additionally recommended to treat the electric motor bearings by completely replacing the standard grease with XADO "Revitalizing" grease
When treatment is not performed
- Screw compressors having parts with 100% wear or macromechanical damage are not subject to treatment
Preparation
- Before starting the treatment, flush or replace the fine oil filter elements
- It is recommended to change the oil in the lubrication system if the residual oil service life is less than 40%
- Before starting the treatment, measure the main operating characteristics of the compressor (item 3.3)
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Vibration level (vibration acceleration, vibration velocity, vibration displacement) | Vibrometers | At fixed points in the vertical, horizontal and axial directions; it is recommended to take measurements in the area of the bearing assemblies or at specially provided control points on the housing of the screw pair. Before starting the treatment and after completion of the full cycle |
| Power consumption (current consumption) of the electric motor | Electricity meters, clamp meters, wattmeters or a multi-parameter instrument for monitoring electrical parameters | On an unloaded compressor and at a fixed pressure load. Before starting the treatment and after completion of the full cycle |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for compressors and bearings (industrial) | 0.5 ml per 1 liter of standard oil for one treatment stage | 8 stages in total; for new compressors or those with initial wear (up to 10%) — 5 stages at the same consumption rate |
| Standard oil for dissolving the gel | 1 part of the gel being dissolved to 5 - 10 parts of oil heated to 40-60°C | The prepared amount of gel is dissolved in a separate container at each stage |
| XADO "Revitalizing" grease | complete replacement of the standard grease in the bearings | Electric motor bearings; packing shall be carried out in accordance with the recommendations of the rules for maintenance and repair of electric motors |
Treatment stages
- Prepare XADO revitalizant gel for compressors and bearings, industrial, at the rate of 0.5 ml per 1 liter of standard oil. Pour a small amount of standard oil into a separate container (at the rate of 1 part of the gel being dissolved to 5 - 10 parts of oil), heated to 40-60°C, dissolve the prepared amount of gel in it and stir thoroughly until completely dissolved. Add the resulting mixture into the oil filler neck of the screw compressor. The compressor is then operated in the standard modeStart of counting the compressor's total operating time
- Adding the gel as in the first stageInterval of 12 - 24 hours of the compressor's total operating time between stages
- Adding the gel as in the first stageInterval of 12 - 24 hours of the compressor's total operating time between stages
- Adding the gel as in the first stageInterval of 12 - 24 hours of the compressor's total operating time between stages
- Adding the gel as in the first stageInterval of 12 - 24 hours of the compressor's total operating time between stages
- Adding the gel as in the first stageInterval of 12 - 24 hours of the compressor's total operating time between stages
- Adding the gel as in the first stageInterval of 12 - 24 hours of the compressor's total operating time between stages
- Adding the gel as in the first stage (the last, 8th stage; for new compressors or those with wear up to 10%, the treatment is limited to 5 stages)Interval of 12 - 24 hours of the compressor's total operating time between stages
After treatment
- The compressor treatment is considered complete after 500 hours of the compressor's total operating time, counted from the beginning of the first treatment stage
- After completion of the full cycle, measure the vibration level at fixed points in the vertical, horizontal and axial directions
- After completion of the full cycle, measure the power consumption (current consumption) of the electric motor on an unloaded compressor and at a fixed pressure load
- Compare the measured characteristics with the initial ones to determine the effectiveness of applying XADO revitalizant compounds
Points to watch
- Only operable screw compressors without parts having 100% wear or macromechanical damage are subject to treatment
- Before treatment, flushing or replacement of the fine oil filter elements is mandatory
- The gel is added only as a solution in standard oil heated to 40-60°C, stirred until completely dissolved
- In addition to treating the oil system of the screw compressor, it is recommended to treat the electric motor bearings with XADO "Revitalizing" grease
Compounds for these units
- Revitalizant gel for compressors and bearingsPiston, screw and centrifugal compressors; rolling and sliding bearings running in an oil bath; machine-tool spindle units and slideways.
Source: Instructions for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 10–11.