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Energy savings through maintenance of York RWB ll 177 model screw compressors

2021-09-04View Original

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A pharmaceutical factory in Jinan, Shandong Province, is one of the leading pharmaceutical manufacturers in the country. To maintain a consistently low temperature in its manufacturing and storage areas, this factory compared various refrigeration units before choosing the York RWB ll 177 model screw compressor unit. This unit boasts excellent performance, and thanks to its variable volume ratio technology, it enables annual energy savings of 215,969 Kwh. At a cost of 0.9 yuan per Kwh, this results in annual savings of 194,372 yuan. Additionally, York’s strong technical capabilities provide reliable after-sales support. For these reasons, the pharmaceutical factory considered the York screw compressor unit to meet all the requirements regarding refrigeration performance, energy savings, and technical quality. It has been shown that over the nearly 20 years of operation of this unit, its failure rate was about 10% lower compared to similar units. This is attributed to two main factors: firstly, the high durability of the unit as a whole, and secondly, the timely maintenance carried out by the factory, which reduced failures such as those involving the unit’s screw rotors. However, in the past two years, as the operating time of this unit at the pharmaceutical factory has increased, problems such as wear and aging have arisen in the compressor, motor, and control system, resulting in significant energy losses. This has reduced the reliability and safety of the refrigeration unit’s operation, posing a serious threat to its long-term stable functioning. The decline in the unit’s performance inevitably had an impact on the manufacturing and storage conditions in this pharmaceutical factory. To mitigate these effects and restore the unit’s performance, the factory sought out various repair providers, including the equipment manufacturer and third-party repair services. The reason for turning to third-party repair services lies in the development and progress in the field of industrial refrigeration technology in our country. This has enabled industrial refrigeration engineers in our country to gain a better understanding of domestic and international brand units as well as to improve their practical skills in the maintenance of such units, thereby raising the technical proficiency of these engineers. This is why the pharmaceutical factory considered third-party maintenance; unsure whether a third party could resolve the unit’s faults, it opted to have the equipment manufacturer first examine the issues, so as to assess their capabilities based on that assessment. In the end, both parties identified problems related to wear and aging of the unit’s bearings, shaft seals, rotor, motor circuits, and control system, and proposed the same solution: 1. Upgrade and maintain the compressor and motor. 2. Upgrade to the latest Qontel 6 motherboard. 3. Upgrade the digital version and analog board. 4. Control system upgraded to the latest QNTO HD. Faced with the same identified faults and solutions presented by both parties, the pharmaceutical factory has two options: either wait for the equipment manufacturer to import the parts from abroad, a process that takes 6 to 8 weeks; in this case, the factory must bear the losses resulting from the shutdown of the equipment during that period, as well as the high costs associated with repairs. Another option is to choose third-party spare parts, which offer a significant price advantage; moreover, engineers are available locally to carry out repairs promptly, thereby **improving the efficiency of unit maintenance. For this reason, the pharmaceutical factory ultimately chose a third-party company. A year later, a third-party engineer called the pharmaceutical factory to inquire about the operation of the unit, expressing a desire to visit the site to inspect its condition. A date was set, and one week later the engineer arrived at the site; he found that the unit was operating well, with no signs of wear or corrosion on the compressor bearings, shaft seals, motor, and other key components. Given the current operating conditions, the compressor did not require any maintenance for the next year. The staff in the control room also informed the engineer that the Quinton 6 motherboard offered improved usability compared to the previous model, with more clear and accurate indicator readings. In conclusion, the engineer determined that the unit was in good working condition. Afterwards, the third-party maintenance provider assessed that the pharmaceutical factory’s attitude and service quality were on par with those of the original manufacturer, and thus a long-term cooperation contract was successfully established. Gonglenghui believes that many foreign-brand products hold a significant market share in China thanks to the uniqueness of their technical features. The slight technological disadvantages of domestic products result in foreign brands charging higher prices for their products as well as for maintenance services. Fortunately, the presence of foreign products allows Chinese engineers to be exposed to and learn more about advanced technical concepts, thereby improving their practical skills. As a result, domestic maintenance providers are able to service screw compressor units from foreign brands, enabling customers to take advantage of benefits such as shorter replacement cycles for spare parts, faster response times from refrigeration engineers, higher efficiency in maintenance, and better overall cost-performance ratios compared to those offered by the equipment manufacturers. Customers who use screw compressor units from foreign brands are also encouraged to give domestic maintenance providers more opportunities to demonstrate their technical capabilities.

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