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Rotating Equipment
CHAPTER 6
ROTARY SCREW COMPRESSOR
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Rotating Equipment
CHAPTER 6
ROTARY SCREW COMPRESSOR
CONTENTS
SECTION - 6.1
Rotary Screw Compressor
Page Number
3
4
SECTION - 6.2
How it Works?
6.2.2 Dry type screw compressor
6.2.3 Oil flooded rotary screw compressor .
6.2.4 Capacity regulation
8
9
12
SECTION - 6.3
Driving System
SECTION - 6.4
Accessories
6.4.1 After coolers and intercoolers .
14
6.4.2 Silencers .
14
15
15
6.4.5 Filters .
15
15
6.4.7 Baseplates .
16
16
SECTION - 6.5
Operation and Preventive Maintenance
6.5.1 Start up .
17
17
18
18
19
19
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SECTION 6.1
ROTARY SCREW COMPRESSOR
6.1.1 Construction of Rotary Screw Compressor
The rotary screw compressors (figure 6.1) consists of two mating rotating
screws, one helical lobed male and one helical grooved female, a housing with
helical timing gear to maintain clearances.
A
B
C
D
E
G
T.S M - RE (Rev. .3) May 2004
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Figure 6.2 Rotor profile of the four lobe male and the six lobe female
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SECTION 6.2
HOW IT WORKS?
6.2.1 How it Works?
The helical screw compressors are divided into two groups. They are:
1- Dry helical screw compressors.
2- Rotary helical screw oil injected compressors.
Both of them from mechanical point of view are similar with minor changes.
Rotary screw compressors employ two intermeshing rotors with helical lobes.
The inlet is located at one end of the rotor.
1. As the rotors revolve, the space between the unmeshing lobes increase
allowing inlet air or gas to fill up the intervening space, until the male
lobe is disengaged from the female lobe along its whole length.
The helices of the male and female rotors are designed to permit
complete charging of the inter lobe space before they remesh.
2. On completion of the filling operation the inlet ends of the male and
female rotors pass the inlet port and become sealed in the casing.
3. With continuing rotation, the male and female lobes begin to re-engage
each other, the volume of this space is reduced and compression begins.
This compression increases with continuing rotation until the built in
pressure ratio is reached and the air (or gas) is discharged through the
outlet port, see figure 6.5
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Figure 6.7 Oil floding system for a rotary screw compressor (simple
drawing)
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SECTION 6.3
DRIVING SYSTEM
Drive is accomplished, with a suitable prime mover, using a directly coupled
flexible coupling. The most common prime mover are electric motor and
internal combustion engines.
On compressors without timing gears the input (drive) shaft is an integral
extension of the male rotor. The prime mover is connected directly to the
male rotor. The female rotor is driven by the male rotor because the
rotors are meshed.
Compressors with timing gears use an independent input shaft mounted
on roller and / or special deep groove ball bearings. The male rotor is
driven by the gear mounted on the input shaft and a mating gear on the
male rotor (see figure 6.1).
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SECTION 6.4
ACCESSORIES
The helical screw compressor operates at moderate speeds (800 to 21,000 rpm)
and may be electric motor, gas or steam turbine or engine driven, direct or
through gear or V-belt for the best design. The low pressure units are normally
sized for direct connected motor speeds. A speed-up gear is used when the
driver and compressor speeds do not match and the horsepower is too great for
V-belt application.
In the present section the accessories which are commonly used with this type
of compressors will be covered. These accessories are:
12345678-
6.4.2 Silencers
Helical screw compressors usually have objectionable noise levels and are
treated accordingly to bring them within allowable limits.
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Inlet and discharge silencers of the sheet metal type with chambers and
perorated tubes and packed spool type are two commonly used designs.
The proper selection is based on the installation and operating requirements.
6.4.5 Filters
Air filters are advisable on air service with atmospheric inlet. Dry type with
replaceable inserts or manually serviced oil bath open mesh type are available.
The former is used where oil free air is required and the latter on general
service.
A lube oil filter is provided in the force feed oil system to protect the bearings,
gears, and oil pump from damage due to dirt, grit, scale, and other foreign
matter that might be in the oil system.
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6.4.7 Baseplates
A welded steel base plate under compressor and driver is often used to provide
case of alignment. If the installation requirements best suit the use of
soleplates, they can be utilized with equal effectiveness.
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Rotating Equipment
SECTION 6.5
OPERATION AND PREVENTIVE MAINTENANCE
Satisfactory performance of a stationary screw compressor requires a good
preventive maintenance program.
The following information is provided as a guide for such a program.
6.5.1 Start up
Start up may be accomplished as follows:
1. Service all equipment (filters moisture separators, prime mover, etc.)
following the equipment manufacturers instructions.
2. Drain condensate (water) from the oil reservoir. Close the drain valve
securely when oil appears.
3. Check the compressor oil reservoir fluid level.
Add oil as necessary to the correct level. Do not overfill.
4. Make certain adequate ventilation and cooling water, if required, is
provided.
5. Start the unit by actuating the electrical controls or starting the engine
following the equipment manufacturers instructions.
6. Observe the unit for leaks, unusual noise, vibration, etc. (Shut down unit
and correct as required.)
7. Observe all instrumentation for proper readings.
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6.5.3.1 Daily
1. Visually inspect the entire unit for leaks, loose hardware, etc. Correct as
required.
2. Service all equipment (filters, moisture separators, etc.) following the
equipment manufacturers instructions.
3. Drain water (condensate) from the oil reservoir. Close the drain valve
securely when oil appears.
Note:
Always drain condensate after the unit has been shut down for a reasonable
length of time (over night).
4. Check the compressor oil reservoir oil level. Add correct type of oil as
required. Do not overfill.
5. With the unit running, observe the oil pressure gages and compare
readings. (Filter in filter out) A difference in pressure reading of 15 PSI
or more indicates that the filter element must be renewed.
6. With the unit running observe the gas pressure gages and compare
readings. (Pressure drop across separator element) A difference in
pressure of 15 PSI or more indicates the separator element is restricted.
If the restriction is caused by dirt or other foreign matter, renew the
separator element.
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Note:
Oil saturation can cause excessive restriction across a separator element.
Always check the separator drain tube and line for restriction, the check valve
(installation and condition) and clean or renew the drain line filter before
condemning a separator element.
Note:
Oil samples may be obtained from the oil reservoir filler opening. (not drain)
Sample should be obtained shortly after shut down.
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