New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors
A new mine screw compressor unit УКГШ with better fire safety than of previously used units is designed and have already integrated into the coal industry of Ukraine. During the whole period of their operation, there was no fire, which usually occurs with compressor units of other types. One more co...
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Інститут геотехнічної механіки імені М.С. Полякова НАН України
2016
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| Цитувати: | New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors / G.V. Kirik, P.Y. Zarkov, G.A. Bondarenko, B.A. Bluss, V.G. Shevchenko // Геотехнічна механіка: Міжвід. зб. наук. праць. — Дніпропетровск: ІГТМ НАНУ, 2016. — Вип. 126. — С. 146-156. — Бібліогр.: 6 назв. — англ. |
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irk-123456789-1364222018-06-17T03:05:07Z New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors Kirik, G.V. Zarkov, P.Y. Bondarenko, G.A. Bluss, B.A. Shevchenko, V.G. A new mine screw compressor unit УКГШ with better fire safety than of previously used units is designed and have already integrated into the coal industry of Ukraine. During the whole period of their operation, there was no fire, which usually occurs with compressor units of other types. One more compressor unit BB is designed, which is equipped with microprocessor control system, high-voltage electric motor, compressor assembly, effective system of air and oil filtration, effective system for vibration reduce, preheating device, unloaded system startup and shutdown. Causes of compressor fault due to the failure of some assemblies were analyzed. Examples of reliability calculations are presented for compressor units and compressor machines in total. Guidelines for improving compressor reliability are: upgrading of compressor design; use of new technology of their exploitation; optimization of their operating modes; use of rapid diagnostic of the compressor state; improvement of preventative maintenance. Створена гвинтова шахтна компресорна установка УКГШ. На підприємствах вугільної промисловості України впроваджені установки компресорні шахтні УКГШ, які мають більш високий рівень пожежної безпеки, ніж застосовувані раніше установки. За час експлуатації не було зафіксовано жодного випадку загоряння, що мало місце при експлуатації компресорних установок інших типів. Розроблена компресорна установка ВВ оснащена мікропроцесорною системою управління, високовольтним електродвигуном, компресорним блоком, ефективною системою фільтрації повітря і масла, ефективною системою зниження вібрації, пристроєм передпускового підігріву, системою розвантажувального пуску і зупинки. Виконано аналіз причин відмови роботи компресорних машин через несправність окремих вузлів. Наведено розрахунки показника надійності вузлів і компресорних машин в цілому. Основними напрямками підвищення надійності компресорних машин є удосконалення конструкції, використання нових технологій експлуатації, оптимізація режимів роботи, використання оперативної діагностики стану, удосконалення системи ППР. Создана винтовая шахтная компрессорная установка УКВШ. На предприятиях угольной промышленности Украины внедрены установки компрессорные шахтные УКВШ, которые имеют более высокий уровень пожарной безопасности, чем применяемые прежде установки. За время эксплуатации не было зафиксировано ни одного случая загорания, что имело место при эксплуатации компрессорных установок других типов. Разработанная компрессорная установка ВВ оснащена микропроцессорной системой управления, высоковольтным электродвигателем, компрессорным блоком, эффективной системой фильтрации воздуха и масла, эффективной системой снижения вибрации, устройством предпускового подогрева, системой разгрузочного пуска и останова. Выполнен анализ причин отказа работы компрессорных машин из-за неисправности отдельных узлов. Приведены расчеты показателя надежности узлов и компрессорных машин в целом. Основными направлениями повышения надежности компрессорных машин является усовершенствование конструкции, использование новых технологий эксплуатации, оптимизация режимов работы, использование оперативной диагностики состояния, усовершенствование системы ППР. 2016 Article New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors / G.V. Kirik, P.Y. Zarkov, G.A. Bondarenko, B.A. Bluss, V.G. Shevchenko // Геотехнічна механіка: Міжвід. зб. наук. праць. — Дніпропетровск: ІГТМ НАНУ, 2016. — Вип. 126. — С. 146-156. — Бібліогр.: 6 назв. — англ. 1607-4556 http://dspace.nbuv.gov.ua/handle/123456789/136422 [622.002.5:621.51/.54].001.5 en Геотехнічна механіка Інститут геотехнічної механіки імені М.С. Полякова НАН України |
| institution |
Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| collection |
DSpace DC |
| language |
English |
| description |
A new mine screw compressor unit УКГШ with better fire safety than of previously used units is designed and have already integrated into the coal industry of Ukraine. During the whole period of their operation, there was no fire, which usually occurs with compressor units of other types. One more compressor unit BB is designed, which is equipped with microprocessor control system, high-voltage electric motor, compressor assembly, effective system of air and oil filtration, effective system for vibration reduce, preheating device, unloaded system startup and shutdown. Causes of compressor fault due to the failure of some assemblies were analyzed. Examples of reliability calculations are presented for compressor units and compressor machines in total. Guidelines for improving compressor reliability are: upgrading of compressor design; use of new technology of their exploitation; optimization of their operating modes; use of rapid diagnostic of the compressor state; improvement of preventative maintenance. |
| format |
Article |
| author |
Kirik, G.V. Zarkov, P.Y. Bondarenko, G.A. Bluss, B.A. Shevchenko, V.G. |
| spellingShingle |
Kirik, G.V. Zarkov, P.Y. Bondarenko, G.A. Bluss, B.A. Shevchenko, V.G. New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors Геотехнічна механіка |
| author_facet |
Kirik, G.V. Zarkov, P.Y. Bondarenko, G.A. Bluss, B.A. Shevchenko, V.G. |
| author_sort |
Kirik, G.V. |
| title |
New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors |
| title_short |
New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors |
| title_full |
New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors |
| title_fullStr |
New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors |
| title_full_unstemmed |
New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors |
| title_sort |
new technologies for pneumoenergy production in the underground mines with the help of the вв and укгш compressors |
| publisher |
Інститут геотехнічної механіки імені М.С. Полякова НАН України |
| publishDate |
2016 |
| url |
http://dspace.nbuv.gov.ua/handle/123456789/136422 |
| citation_txt |
New technologies for pneumoenergy production in the underground mines with the help of the ВВ and УКГШ compressors / G.V. Kirik, P.Y. Zarkov, G.A. Bondarenko, B.A. Bluss, V.G. Shevchenko // Геотехнічна механіка: Міжвід. зб. наук. праць. — Дніпропетровск: ІГТМ НАНУ, 2016. — Вип. 126. — С. 146-156. — Бібліогр.: 6 назв. — англ. |
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Геотехнічна механіка |
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ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 146
UDC [622.002.5:621.51/.54].001.5
Kirik G.V., D.Sc. (Tech.), Associate Professor,
Zarkov P.Ye., Ph.D (Tech.)
(Concern «NICMAS»)
Bondarenko G.A., Ph.D (Tech.), Professor
(SumSU),
Bluss B.A., D.Sc. (Tech.), Professor,
Shevchenko V.G., D.Sc. (Tech.), Senior Researcher
(IGTM NAS of Ukraine)
NEW TECHNOLOGIES FOR PNEUMOENERGY PRODUCTION IN
THE UNDERGROUND MINES WITH THE HELP OF THE ВВ AND УКГШ
COMPRESSORS
Кирик Г.В., д-р техн. наук, доц.,
Жарков П.Е., канд. техн. наук,
(Концерн «НІКМАС»),
Бондаренко Г.А., канд. техн. наук, проф.
(СумДУ),
Блюсс Б.О., д-р техн. наук, професор,
Шевченко В.Г., д-р техн. наук, ст. наук. співроб.
(ІГТМ НАН України)
НОВІ ТЕХНОЛОГІЇ ВИРОБКИ ПНЕВМОЕНЕРГІЇ В ПІДЗЕМНИХ
УМОВАХ ШАХТ ЗА ДОПОМОГОЮ КОМПРЕСОРІВ ВВ І УКГШ
Кирик Г.В., д-р техн. наук, доц.,
Жарков П.Е., канд. техн. наук,
Бондаренко Г.А., канд. техн. наук, профессор
(Концерн «НИКМАС»),
Блюсс Б.А., д-р техн. наук, проф.
Шевченко В.Г., д-р техн. наук, ст. научн. сотр.
(ИГТМ НАН Украины)
НОВЫЕ ТЕХНОЛОГИИ ВИРАБОТКИ ПНЕВМОЭНЕРГИИ В
ПОДЗЕМНЫХ УСЛОВИЯХ ШАХТ С ПОМОЩЬЮ КОМПРЕССОРОВ
ВВ И УКВШ
Abstract. A new mine screw compressor unit УКГШ with better fire safety than of previously
used units is designed and have already integrated into the coal industry of Ukraine. During the
whole period of their operation, there was no fire, which usually occurs with compressor units of
other types. One more compressor unit BB is designed, which is equipped with microprocessor con-
trol system, high-voltage electric motor, compressor assembly, effective system of air and oil filtra-
tion, effective system for vibration reduce, pre-heating device, unloaded system startup and shut-
down. Causes of compressor fault due to the failure of some assemblies were analyzed.
Examples of reliability calculations are presented for compressor units and compressor ma-
chines in total. Guidelines for improving compressor reliability are: upgrading of compressor de-
© Г.В. Кирик, П.Е. Жарков, Г.А. Бондаренко, Б.А. Блюсс, В.Г. Шевченко, 2016
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 147
sign; use of new technology of their exploitation; optimization of their operating modes; use of rap-
id diagnostic of the compressor state; improvement of preventative maintenance.
Keywords: compressors, new technologies, pneumatic energy, underground mining conditions,
reliability and safety.
Energy efficiency, reduction of accident rate and man-caused impacts on the envi-
ronment are the most pressing problems for the coal mines. In order to be successful,
the industry should speed up its technical upgrading and complex renewal of the mine
fixed asset. It should be noted that operation life of the Ukrainian mines is quite long,
therefore, investments into their modernization are urgently required.
Improvement of compressed-air supply systems in the mines is one of the key
guidelines for saving energy in the coal industry. Significant reserves for energy sav-
ing in the compressed-air production for the coal mines lie in reduction of its produc-
tion cost and improvement of pneumatic system for compressed air supplying. An
alternative to the existing production technology, which assumes installation of pow-
erful compressor stations on the earth surface, is creation of modular underground
compressor stations on the base of mobile screw compressor units with their alloca-
tion directly in the face, including in the dead ends, optimally close to the under-
ground consumers of the compressed air [1, 2].
The screw compressor unit.
A pneumohydraulic circuit of the designed
screw compressor unit [3] is shown in Fig. 1,
and its vertical and horizontal sections are shown
in Fig. 2. The screw compressor unit works as
follows. When the unit works, air is sucked
through the air filter 3 into the compressor 1, to
where the cooled oil also flows from the cooler
16 through the line 15. This cooled oil is needed
for cooling the compressed air, sealing gaps be-
tween the working bodies of the compressor and
lubricating the bearings. The oil is mixed with
the air and forms an oil-air mixture, which is
compressed in the compressor 1 to the set oper-
ating pressure and then enters the oil separator
5. On two levels of the oil separator 5, the air is
separated from the oil and then is supplied to
the customer through the minimal pressure valve 6 and distribution valves on the dis-
pensing tube 7.
Sensors of automation systems and connected with them devices force the auto-
matic system to response when operating parameters of the unit exceed the boundary
values. Two temperature sensors 8 and 9 of the automation system are installed in the
injection line 4 after the screw compressor 1; they are designed on different physical
principles of operation and provide reliable response when the oil-air mixture tem-
perature exceeds the set parameters.
Figure 1 - Pneumohydraulic scheme of
screw compressor unit
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 148
The temperature sensor 10 of the automation system protection line 11 is installed
in the space of the oil separator 5 and ensures more reliable response when oil tem-
perature in the oil separator 5 reaches critical values.
When temperature of the drive cover exceeds the set values, a temperature sensor
12, which is installed on the drive cover, emergently switches the compressor 1 off.
In event of a fire risk, the temperature sensor 13 of the fire suppression system, which
is installed above the oil separator 5, switches the device 14, which is installed over
the oil separator 5, and which feeds fire extinguishing agents and effectively localizes
a possible fire in the area of the main element of the shaft compressor unit, and which
contains the most part (90 %) of fire-safe substance. In event of critical increase of
methane concentration, the methane sensor 17 switches the automation system on;
the sensor 17 is installed on the top of the compressor unit casing, and such location
ensures its operation in area with initial methane accumulation in the upper part of
the casing.
The main stages of the mobile shaft compressor unit УКГШ designing are as fol-
lows:
1. To receive from the MacNDI an expert’s conclusion concerning compliance of
the high-risk equipment with requirements of regulations on labor protection and in-
dustrial safety, and to get a permit for testing the equipment in the Ukrainian mines.
The received expert’s conclusion states that the unit УКГШ-7,5/7В5 is in harmony
with the relevant requirements of regulations and it is permitted to test the unit (ap-
proval test and operation) in the underground dead ends, including mines with the
risk of high gas and dust content, in accordance with the "The Safety Rules For the
Coal Mines".
Figure 2 - Screw compressor unit: a) horizontal and b) vertical section
2. To develop and approve Technical Specifications.
3. To conduct, together with the M.M. Fedorov NIIGM and NIIHS “Respirator”,
acceptance tests of the unit prototype at the Dobropolska Mine of the SE Dobropoly-
eugol.
4. To obtain from the Donetsk Technical Expert Centre of the Derzgirprom-
naglyad of Ukraine (DTEC) an expert’s conclusion on the high-risk equipment com-
pliance with requirements of regulations on labor protection and industrial safety.
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 149
5. To obtain, on the basis of the DTEC conclusion, a permit for the units putting
into operation in the Ukrainian mines.
6. To put into operation a docking series with further widespread implementation
of the mobile shaft compressor units УКГШ in the Ukrainian mines.
In 2012, the certificates of conformity with technical regulations on the safety
machinery and equipment were received on the basis of certification study protocols
and periodic testing protocols for the units УКГШ-5/7 УКГШ-7.5 / 8 УКГШ-15/7.
Assessment of and ways for improving reliability of the compressor units and
assemblies.
The Ukrainian coal producers have already implemented more than 1148 com-
pressor units УКГШ-7.5/7; УКГШ 10/7; УКГШ-15/7 designed by NIKMAS Con-
cern. Their productivity is 7,5-15 m3/min. The units are in operation since 2001.
The shaft compressor units УКГШ have higher level of fire safety than previously
used units ШВ-5. During the whole period of their operation, there was no fire, which
usually occurs with compressor units of other types [4-6].
Design of the shaft screw compressor units
was improved (Fig. 3), and statistics of failures
of the compressor modules and assemblies was
gathered for the whole period of their operation
in the coal mines. The systematic analysis
shows that the key destabilizing factors affect-
ing the compressors technical and economic pa-
rameters is wear of the loaded assemblies,
which is accompanied by increased power con-
sumption by the drive system or by termination
of their operation. Especially critical is wear of
the screw pairs, because any increase of clear-
ance between them leads to significant reduction
of their efficiency.
Dimension types of the shaft screw compressor units are shown in the Table 1.
In order to provide more effective air cleaning in the dusty mines, the units are
equipped with advanced filtration system and, in particular, air filter of the oil-inertial
type, which ensure operation of the unit at dust content up to 100 mg/m3. The com-
pressor units of the BB-25/8 M1 У2; BB-32/8 M1 У2; BB-32/8 T2 types are used as
an integral part of the drilling equipment (Fig. 4, 5).
In the process of parameter optimization for the first series of machines, design of
the unit ВВ-32/8M1У2 was essentially improved by integration of additional equip-
ment: vertical separator-oil filter, thanks to which oil drainage does not exceed 3
mg/m3 and interval for the oil relubrication is 3500 hours; thermostat, which simpli-
fies process of starting and heating; and electric motor of special design for boring
machine.
The compressor block and electromotor are connected with each other by a com-
mon casing and are installed on the shock absorbers, therefore, periodic alignment is
not needed any more and load on the bearings and vibration rate are reduced; besides,
Figure 3 – The shaft screw compres-
sor unit УКГШ-10/7 A У2 with elec-
tric protection system
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 150
design of minimal-pressure valve and drain valve was improved in terms of their reli-
ability; oil cooler was upgraded (its weight and dimensions were reduced); more reli-
able temperature sensors and solenoid valves were installed; performance control sys-
tem was modernized: now electric motor starts when compressor is unloaded, thus,
reliability of the electric motor and starting equipment is improved; the compressor
unit was modified by way of integration of the controller.
Table 1 – Specification of the shaft screw compressor units
Parameters and
design features
УКГШ-
4/7
УКГШ-
5/7
УКГШ-
6/7
УКГШ-
7,5/7
УКГШ-
10/7
УКГШ-
11/7
УКГШ-
15/7
УКГШ-
20/7
Compressible
working agent
Air
Volumetric
productivity, cal-
culated for the ini-
tial conditions,
m3/min
4,0 5,0 6,15 7,5 10,0±1,0 11,0±0,5 14,5±0,72 20,0±1,0
Initial pressure,
nominal, kg/cm2 1,03
Final pressure,
nominal, kg/cm2
6,0±7,0 6,0±7,0 6,0±7,0 6,0±7,0 6,0±7,0 6,0±8,0 6,0 6,0
Initial temperature
maximal, 0C
minimal, 0C
+35
-5
+35
-5
+35
-5
+35
-5
+40
-5
+40
-5
+35
-5
+35
-5
Final temperature,
0C, not higher than
without final cool-
er
with final cooler
100
200 higher than the intake air temperature
Power consumed
by the compressor,
kW
25 31 37 47 54±57 73
not more
than 90
not more
than 110
Specific power
consumption, kW
m3/hour
6,25 6,2 6,17 6,27 5,7-0,3 6,63 6,2 5,8
Power of the in-
stalled electric mo-
tor, kW (asynchro-
nous, three-phase,
explosionproof)
30 37 45 55 55 or 75 75 90 110
Oil consumed for
the air drainage,
g/m3 of air, not
higher than
0,02 0,02 0,02 0,02 0,02 0,02 0,02 0,02
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 151
Sound level at a
distance
1 m, dB, not high-
er than
7 m, dB, not high-
er than
89
80
89
80
89
80
89
80
90
80
93
80
93
80
93
80
Synchronous
speed,
s-1 (rev/min)
25 (1500) 25 (1500) 25 (1500) 25 (1500)
25
(1500)
25
(1500)
25
(1500)
25 (1500)
or 50
(3000)
Supply voltage, V 380/660 380/660 380/660
380/660
або
660/1140
380/660 380/660 380/660
380/660
or
660/1140
Possible starter
installation in the
unit body
+ + + + + + + +
Starter type ПВІ125 ПВІ125 ПВІИ125 ПВІ125 ПВІ160 ПВІ160 ПВІ250 ПВІ250
Protection system ПГЗ* or УЗКВ** or microprocessor
Overall dimen-
sions
2200
1050
1500
2200
1050
1500
2200
1050
1500
2200
1050
1500
2800
1100
1400
2800
1150
1485
3140
1140
1600
3200
1140
1640
without
starter
length
width
height
With inte-
grated start-
er
length
width
height
2600
1050
1500
2600
1050
1500
2600
1050
1500
2600
1050
1500
3200
1100
1400
2800
1150
1485
3200
1140
1600
3200
1140
1640
Weight, kg 1500 1500 1500 1500 3000 3000 2900 3000
Base of the
transport trolley,
mm/rail, mm
1250/600
(900)
1250/600
(900)
1250/600
(900)
1250/600
(900)
1650/600
(900)
1650/600
(900)
1650/600
(900)
1650/600
(900)
Cleaning of the
intake air (effi-
ciency)
I variant - dry filter
II variant - com-
bined (dry + oil
inertial filters)
+
(10 to 30
mg/m3)
+
(up to
100
mg/m3)
+
(10 to 30
mg/m3)
+
(up to
100
mg/m3)
+
(10 to 30
mg/m3)
+
(up to
100
mg/m3)
+
(10 to 30
mg/m3)
+
(up to
100
mg/m3)
+
(10 to 30
mg/m3)
+
(up to
100
mg/m3)
+
(10 to 30
mg/m3)
+
(up to
100
mg/m3)
+
(10 to 30
mg/m3)
+
(up to 100
mg/m3)
+
(10 to 30
mg/m3)
+
(up to
100
mg/m3)
Mobile, on wheels + + + + + + + +
Stationary + + + + + + + +
Note: * ПГЗ - version with pneumohydraulic protection system;
** УЗКВ - version with electrical protection system
The microprocessor control unit makes possible to control all compressor unit op-
erations. The controller is equipped with independent powerful memory, which can
store the compressor current settings and modes and operator’s actions for a long pe-
riod of time.
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 152
Figure 4 – The compressor unit for drilling
machine
Figure 5 - Drilling machine СБШ- 250МНА-
32КП with compressor unit ВВ-50/8У2
The compressor unit ВВ-50/8У2 is equipped with microprocessor control system,
high-voltage electric motor, compressor assembly, effective system of air and oil fil-
tration, system for effective vibration reduction, pre-heating device, system for un-
loaded starting and shutdown.
A block diagram of the unit with elements and components, which impact on the
compressor machine reliability, is shown in Fig. 6.
Figure 6 - The hierarchical structure of the compressor machine
Calculations of reliability of compressor assemblies and compressor machine in
total are shown in Table 2. The obtained life per elements is from 2107 hours to
13,162 hours, which is much better than values specified in the Technical Specifica-
tion. Probability of the element failure-free operation ranges between 0.975 and
Electromotor
V-belt transmission
Compressor assembly
Previous air cooler
Final air cooler
Moisture separator
Tubular electroheater
Previous filter
Fine filter
Suction filter
Fan with electric motor
Cooling system
Control system
Controller
Pressure, temperature,
humidity sensors
Condensate drainage
Condensate drainage
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 153
0.9995. Probability of failure-free operation during the specified system life is
0.9434. Average operation period till some element failure ranges between 20 000
hours and 125 000 hours. Probability of the element failure-free operation ranges be-
tween 0.827 and 0.998.
Table 2 - Estimated reliability of the compressor elements
№
p /
p
Item Average inter-
val between
the failures,
hours
Density of
probable
failure
Probability of
failure-free op-
eration
Intensity
of failure
The obtained
failure-free
operation peri-
od
1 Controller 39 736 1,7810-5 0,827 2,0310-5
2 Air supply
unit
85 969 9,210-8 0,9975 9,2210-8 9057
3 Previous air
cooler
50 000 5,2710-7 0,995 8,9910-7 5288
4 Condensate
drainage
30 000 2,210-6 0,987 2,2310-6 3160
5 Coarse filter 100 000 2,0310-8 0,998 2,0310-8 10 536
6 Fine filter 100 000 2,0310-8 0,998 2,0310-8 10 536
7 Electric heat-
er
25 000 4,0410-6 0,978 4,1310-6 2634
8 Pressure sen-
sor
125 000 8,710-8 0,9975 8,7110-8 13 162
9 Temperature
sensor
20 000 8,910-7 0,96 8,9410-7 2107
Fig. 7 shows guidelines for improving the compressor machine reliability, which
were realized in this research. Failures of some subsystems of the compressor park
are random variables. Causes of compressor failures due to the failure of individual
blocks were analyzed (Fig. 8).
Figure 7 – Guidelines for improving reliability of the
compressor machines
1 - oil filter; 2 - thermometer; 3 - com-
pressor assembly; 4 - controller; 5 - elec-
tric motor; 6 - suction valve; 7 - tempera-
ture controller
Figure 8 - Histogram of relative frequency
of failure of the compressor assemblies
and parts in process of their operation in
the coal mines
Improvement of compressor
and assembly reliability
New technolo-
gies of opera-
tion
Optimization
of operation
modes
Improve-
ment of
design
Rapid diagnosis Improvement of
preventive
maintenance
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 154
Conclusions.
1. A new shaft screw compressor unit was designed. When the unit operates, air is
sucked through the air filter into the compressor, to where the cooled oil also flows from
the cooler. The oil is mixed with the air and forms an oil-air mixture, which is com-
pressed in the compressor to the set operating pressure and then enters the oil separator.
On two levels of the oil separator, the air is separated from the oil and then is supplied to
the customer through the minimal pressure valve and distribution valves on the dispens-
ing tube.
2. The Ukrainian coal producers have already implemented more than 1148 com-
pressor units УКГШ-7.5/7; УКГШ 10/7; УКГШ-15/7 designed by NIKMAS Concern.
Their productivity is 7,5-15 m3/min. The units are in operated since 2001. The shaft
compressor units УКГШ have higher level of fire safety than previously used units ШВ-
5. During the whole period of their operation, there was no fire, which, which usually
occurs with compressor units of other types.
3. Calculations of reliability of compressor blocks and compressor machine in total
are shown in Table 2. The element life is from 2107 hours to 13,162 hours, which is bet-
ter than values specified in the Technical Specification. Probability of the element fail-
ure-free operation ranges between 0.975 and 0.9995. Probability of failure-free operation
during the specified system life is 0.9434. Average operation period till any element
failure ranges between 20 000 hours and 125 000 hours. Probability of the element fail-
ure-free operation ranges between 0.827 and 0.998.
4. The key guidelines for improving the compressor reliability include: improvement
of design; new technologies of operation; optimization of operation modes; rapid diag-
nostic of technical state; improvement of preventive maintenance system.
________________________________
REFERENCES
1. Gryaduschiy B.A., Kirik G.V., Koval A.N., Loboda V.V., Zharkov P.E. and Lavrenko A.M. (2008),
«About the problems of pneumoenergetical complex of mines», Kompressornoye i energeticheskoye mashi-
nostroyeniye, no 1 (11), pp. 2-5.1.
2. Loboda, V.V. (2011), «Perfection of energy-saving technology of making of pneumoenergy in the
underground terms of mines», Kompressornoye i energeticheskoye mashinostroyeniye, no 4 (26), pp. 6-8.
3. Kirik G.V., Zharkov P.E., Gryaduschiy B.A., Koval A.M., Negreba R.Z., Belozorov V.O., Lavrenko
O.M. and Loboda V.V.(2009), Ustanovka kompresorna gvintova shakhtna [Setting a compressor spiral
mine], Ukraine,Patent 40448.
4. Bondarenko G.A. and Kirik G.V. (2012), Kompressornyie stantsii: ucheb. pos.: v 2 ch. Vol.1 :
Vozdushnyie kompressornyie stantsii [Compressor stations: studies. P.1 : Air compressor stations], Sumyi,
SumGU, 344 p.
5. Bulat A.F. and Kirik G.V. (2014), «Energy-effective compressor machines in the processes of booty
of coal and methane», Geo-Technical Mechanics, no. 115, pp. 3-15.
6. Bulat A.F., Kirik G.V. and Shevchenko V.G. (2014), «Complex decision of problems of safety at de-
velopment of deposits of hydrocarbons with the use of compressor equipment», Geo-Technical Mechanics,
no. 119, pp. 3-13.
СПИСОК ЛИТЕРАТУРЫ
1. О проблемах пневмоэнергетического комплекса шахт / Б.А. Грядущий, Г.В. Кирик, А.Н.
Коваль [и др.] // Компрессорное и энергетическое машиностроение. – 2008. - № 1 (11). - С. 2-5.1.
2. Лобода, В.В. Вдосконалення енергозберегаючої технології вироблення пневмоенергії в
підземних умовах шахт / В.В. Лобода // Компрессорное и энергетическое машиностроение. - 2011. -
№ 4 (26). - С.6-8.
3. Патент 40448 Україна, F04C 29/02. Установка компресорна гвинтова шахтна / Кирик Г.В.,
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 155
Жарков П.Є., Грядущий Б.А., Коваль А.М., Негреба Р.З., Бєлозьоров В.О., Лавренко О.М., Лобода
В.В. / Україна / u200812865; Заявл. 04.11.2008, Опубл. 10.04.2009, Бюл. № 7.
4. Бондаренко, Г.А. Компрессорные станции: учеб. пос.: в 2 ч. Ч.1 : Воздушные компрессорные
станции / Г.А. Бондаренко, Г.В. Кирик. – Сумы: Изд-во СумГУ, 2012. – 344 с.
5. Булат, А.Ф. Энергоэффективные компрессорные машины в процессах добычи угля и метана /
А.Ф. Булат, Г.В. Кирик // Геотехнічна механіка. – 2014. – Вып. 115. – С. 3-15.
6. Булат, А.Ф. Комплексное решение проблем безопасности при разработке месторождений
углеводородов с применением компрессорного оборудования / А.Ф. Булат, Г.В. Кирик, В.Г.
Шевченко // Геотехнічна механіка. – 2014. – Вып. 119. – С. 3–13.
–––––––––––––––––––––––––––––––
About the authors
Kirik Grigory V., Doctor of Technical Sciences (D. Sc), Associate Professor, President, Concern
“NICMAS”, Sumy, Ukraine, g.kirik@nicmas.com.
Zarkov Pavel E., Candidate of Technical Sciences (Ph.D.), Vice-President, Concern “NICMAS”, Sumy,
Ukraine, p.zharkov@nicmas.com.
Bondarenko German A., Candidate of Technical Sciences (Ph.D.), Professor, Professor of Department
of Engineering Thermophysics, Sumy State University Ministry of Education and Science of Ukraine, Sumy,
Ukraine.
Bluss Boris O., Doctor of Technical Sciences (D. Sc), Professor, Head of Department of geodynamic
system and vibration technologies, M.S. Polyakov Institute of Geotechnical Mechanics under the National
Academy of Sciences of Ukraine (IGTM, NASU), Dnepropetrovsk, Ukraine.
Shevchenko Vladimir G., Doctor of Technical Sciences (D. Sc), Senior Researcher, Scientific Secretary
of the Institute, M.S. Polyakov Institute of Geotechnical Mechanics under the National Academy of Sciences
of Ukraine (IGTM, NASU), Dnepropetrovsk, Ukraine, V.Shevchenko@nas.gov.ua.
Про авторів
Кирик Григорій Васильович, доктор технічних наук, доцент, президент, Концерн «НІКМАС»,
Суми, Україна, g.kirik@nicmas.com.
Жарков Павло Євгенович, кандидат технічних наук, віце-президент, Концерн «НІКМАС», Суми,
Україна, p.zharkov@nicmas.com.
Бондаренко Герман Андрійович, кандидат технічних наук, професор, професор кафедри
технічної теплофізики, Сумський державний університет МОН України, Суми, Україна.
Блюсс Борис Олександрович, доктор технічних наук, професор, завідувач відділом
геодинамических систем і вібраційних технологій, Інститут геотехнічної механіки ім. Н.С. Полякова
Національної академії наук України (ИГТМ НАНУ), Дніпропетровськ, Україна.
Шевченко Володимир Георгійович, доктор технічних наук, старший науковий співробітник,
учений секретар інституту, Інститут геотехнічної механіки ім. Н.С. Полякова Національної академії
наук України (ИГТМ НАНУ), Дніпропетровськ, Україна, V.Shevchenko@nas.gov.ua.
__________________________________________
Анотація. Створена гвинтова шахтна компресорна установка УКГШ. На підприємствах
вугільної промисловості України впроваджені установки компресорні шахтні УКГШ, які
мають більш високий рівень пожежної безпеки, ніж застосовувані раніше установки. За час
експлуатації не було зафіксовано жодного випадку загоряння, що мало місце при
експлуатації компресорних установок інших типів. Розроблена компресорна установка ВВ
оснащена мікропроцесорною системою управління, високовольтним електродвигуном,
компресорним блоком, ефективною системою фільтрації повітря і масла, ефективною
системою зниження вібрації, пристроєм передпускового підігріву, системою
розвантажувального пуску і зупинки. Виконано аналіз причин відмови роботи компресорних
машин через несправність окремих вузлів. Наведено розрахунки показника надійності вузлів
і компресорних машин в цілому. Основними напрямками підвищення надійності
компресорних машин є удосконалення конструкції, використання нових технологій
експлуатації, оптимізація режимів роботи, використання оперативної діагностики стану,
удосконалення системи ППР.
Ключові слова: компресори, нові технології, пневмоенергія, підземні умови шахт,
надійність і безпека.
http://org.i.ua/js/compose/?id=6664488
mailto:V.Shevchenko@nas.gov.ua
http://org.i.ua/js/compose/?id=6664488
mailto:V.Shevchenko@nas.gov.ua
ISSN 1607-4556 (Print), ISSN 2309-6004 (Online) Геотехнічна механіка. 2016. № 126 156
Аннотация. Создана винтовая шахтная компрессорная установка УКВШ. На
предприятиях угольной промышленности Украины внедрены установки компрессорные
шахтные УКВШ, которые имеют более высокий уровень пожарной безопасности, чем
применяемые прежде установки. За время эксплуатации не было зафиксировано ни одного
случая загорания, что имело место при эксплуатации компрессорных установок других
типов. Разработанная компрессорная установка ВВ оснащена микропроцессорной системой
управления, высоковольтным электродвигателем, компрессорным блоком, эффективной
системой фильтрации воздуха и масла, эффективной системой снижения вибрации,
устройством предпускового подогрева, системой разгрузочного пуска и останова. Выполнен
анализ причин отказа работы компрессорных машин из-за неисправности отдельных узлов.
Приведены расчеты показателя надежности узлов и компрессорных машин в целом.
Основными направлениями повышения надежности компрессорных машин является
усовершенствование конструкции, использование новых технологий эксплуатации,
оптимизация режимов работы, использование оперативной диагностики состояния,
усовершенствование системы ППР.
Ключевые слова: компрессоры, новые технологии, пневмоэнергия, подземные условия
шахт, надежность и безопасность.
Стаття поступила до редакції 28.12.2015
Рекомендовано до друку д-ром техн. наук Шевченко Г.О.
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