Turbocompressor K-250
A large turbocompressor station. The effect is measured not by pressure but by electricity: how many kilowatt-hours are spent per thousand cubic meters of air.
K-250 air turbocompressor station, 1800 l oil system, up to 10 000 rpm
The class norm is 0.8 ml per liter. For this machine there are two revisions of the applied procedure: 1.2 ml/l in 3 stages and 0.9 ml/l in 4 stages. The total is the same in both — 6480 ml; which one to apply is decided by the XADO engineer. Screw and centrifugal compressors →
What is treated
- A serviceable turbocompressor with no parts at 100 % wear and no macromechanical damage.
- Fine oil filters flushed or replaced.
- It is strongly recommended to carry out the treatment on fresh or guaranteed clean oil.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Electricity consumption over a fixed interval | electricity meter | For example, over 20 minutes recalculated to an hour; separately — at idle running. |
| Specific electricity consumption per 1000 m³ of air | calculation from the meter | Measurements are comparable only at the same temperature of the air being pumped: a difference of 5–10 °C has a noticeable effect. |
| Vibration level of each bearing support | vibrometer | Vibration displacement, vibration velocity, vibration acceleration in the horizontal, vertical and axial directions. |
| Operating temperature of the plain bearings | thermometer | At the same cooling intensity. |
| Tooth thickness of the step-up gearbox | gear tooth vernier caliper | Over the constant chord, with a description of the contact patterns. |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| Gel for compressors and bearings — 3-stage revision | 1.2 ml per 1 liter of standard oil per stage | 1800 l system: 2160 ml per stage, 6480 ml in total. The interval between stages is not earlier than 8 and not later than 16 hours. |
| The same gel — 4-stage revision | 0.9 ml per 1 liter of standard oil per stage | 1620 ml per stage, 6480 ml in total. The second stage after 24 hours, the third and fourth — after 12 hours. |
Treatment stages
- Dilute the gel in 4–7 l of standard oil heated to 50–60 °C, stir until completely dissolved and add to the oil system of the station.Start of the total operating time count
- The second stage — the same as the first.After 8–16 hours of total operating time
- The third stage — the same as the first.After another 8–16 hours of operating time
After treatment
- The treatment is completed after 450 hours of total operating time.
- Electricity consumption is compared over equal periods — for example, the month before and the month after.
Points to watch
- Electricity measurements are comparable only at a similar temperature of the air being pumped: a difference of 5–10 °C noticeably affects the result.
- At the first stage, 10–15 minutes of idle running, then under load; at subsequent stages idle running is not mandatory.
Where К-250 has already been treated
- Rosava JV JSC · 2004↓ 5.3% — power consumed by the motor at no load, 743.04 → 703.4 kW
Source: XADO applied procedure, lead engineer I. N. Sharaikin. Class norm — instruction IE-24.6-25612000-005-2008, procedure No. 2. Analysis: state/DRIVE_METHODS.md.