Turbocompressor K-500: less electricity with no unit shutdown

Idle power draw fell, stator current dropped, the effect held at the repeat check. Turbocompressor K-500, KGGMK “Krivorozhstal”. Ukraine · 2003. 6.1 %, 4.8 %.

KGGMK “Krivorozhstal”, electrical engineering laboratory shop (TsETL), oxygen production · report approved by V. F. Volkov, Deputy General Director for Power Engineering of the works; treatment — JV “AVIS”

Kryvyi Rih, Ukraine · treatment 25–27.12.2002 · report dated 18.02.2003

PRODUCTXADO revitalizantsXADO technology · treatment under normal operating duty

TEST OBJECTTurbocompressor K-500ser. No. 9828 · electric motor, gearbox, bearing supports No. 1–9

DOCUMENT TYPEReport of the plant commission
approved by the works management

Key results

↓6.1%

power drawn by the electric motor at idle, 2682.5 → 2518.0 kWh

↓4.8%

stator current of the electric motor at idle, 250 → 238 A

UNIT ASSEMBLY	TREATMENT AND RUNNING TIME	WHAT WAS MEASURED
Turbocompressor K-500, ser. No. 9828	Treated 25–27.12.2002 without taking out of service and without disassembly	Stator and rotor current, phase currents, power draw
Drive gearbox	Treated as part of the unit; check measurements after 435 and 890 h	Vibration of bearing supports No. 4–7
Electric motor	Treated as part of the unit; check measurements after 435 and 888 h	Vibration of bearing supports No. 8–9, phase currents

Idle duty (P = 0.8 atm) — electrical parameters

PARAMETER	BEFORE TREATMENT	AFTER 435 H	AFTER 888 H
Power drawn per 1 hour	2682.5 kWh	2518.0	2518.0
Stator current	250 A	238	—
Rotor current	200 A	200	200
Phase A current	246.4 A	244.0	248.0
Phase B current	249.6 A	240.0	225.6
Phase C current	260.8 A	237.6	225.6

Phase currents were measured with a VAF-85 instrument at a transformation ratio of 80, power — by the in-service meter. According to the conclusions of the report, the average current at idle dropped by 4.6 %.

Conclusions of the commission

The commission of KGGMK “Krivorozhstal” recorded: 1. As a result of the treatment of turbocompressor K-500 (ser. No. 9828) by the XADO technology, the current in idle duty decreased on average by 4.6 %, the power drawn by the electric motor at idle decreased by 164.5 kW per hour (6.1 %), which makes it possible to obtain savings amounting to 15500 UAH per month and to fully recoup the cost of the restorative repair of the turbocompressor carried out by the XADO technology. 2. The insignificant decrease (and on some supports an increase) of the vibration level after the turbocompressor had run 435 hours is explained by the fact that during the treatment period (after 360 hours of operation) an emergency shutdown was carried out because of a false tripping of the rotor axial shift protection, together with disassembly of the thrust bearing assembly for the purpose of inspection.

The results relate to turbocompressor K-500 (ser. No. 9828) of the oxygen production facility of KGGMK “Krivorozhstal” and to idle duty at a pressure of 0.8 atm; on other equipment and in other duties the figures may differ. The original report is published in full and available for download.

Current equivalent

Revitalizant gel for compressors and bearingsCompressors · bearings · spindles
Revitalizant gel for gearboxesGearboxes · transmissions · gear drives

How such units are treated: Compressor Reduction gearbox Bearings

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