THE OIL-FLOODED ROTARY SCREW COMPRESSOR HCM CITY UNIVERSITY OF TECHNOLOGY

REFRIGERATION THERMAL TECHNOLOGY

INDUSTRIAL REFRIGERATION

CHAPTER: 14 THE OIL-FLOODED ROTARY SCREW COMPRESSOR

Lecturer: Dor. BI NGC HNG

Reporter: TRN XUN AN

THE OIL-FLOODED ROTARY SCREW COMPRESSOR

CONTENTS
GENERAL TYPES OF COMPRESSORS HELICAL ROTORS ADVANTAGES OF THE ROTARY SCREW COMPRESSOR APPLICATIONS FOR THE ROTARY SCREW COMPRESSOR VAPOR RECOVERY SIZING A ROTARY SCREW COMPRESSOR

THE OIL-FLOODED ROTARY SCREW COMPRESSOR General The rotary screw compressor has attracted increased attention in the gas industry during the last decade as an ideal compressor for low pressure/high capacity op-erations, with low pressure dened as suction pressure at or near zero psig and discharge pressure at less than 400 psig. The rotary screw is a positive displacement compressor. The rotary screw gleans honors for its simplicity, low cost, easy maintenance and almost pulsation-free ow (dng chy xung ng)

THE OIL-FLOODED ROTARY SCREW COMPRESSOR Benets offered by rotary screw compressors include: Simple maintenance Low maintenance costs Long compressor life Full use of driver horsepower Low operating expense Low purchase price High compression ratios (Rc) up to 16 Rc per stage Operation at low suction pressure up to 26 inches of vacuum Light weight Compactness

THE OIL-FLOODED ROTARY SCREW COMPRESSOR

THE OIL-FLOODED ROTARY SCREW COMPRESSOR

THE OIL-FLOODED ROTARY SCREW COMPRESSOR 14.1 TYPES OF COMPRESSORS Rotary compressors may be either positive displacement or dynamic compressors The positive displacement rotary utilizes either vanes, lobes or screws to literally pack the gas into the discharge line. The dynamic compressor works on transfer of energy from a rotating set of blades to a gas, and then discharges the gas into a diffuser (ng khuych tn) where the velocity is reduced and its kinetic energy is converted to static pressure.

THE OIL-FLOODED ROTARY SCREW COMPRESSOR

THE OIL-FLOODED ROTARY SCREW COMPRESSOR

THE OIL-FLOODED ROTARY SCREW COMPRESSOR Reciprocating compressors consist of a piston acting within a cylinder to physically compress the gas contained within that cylinder. They may be either single acting or double-acting, and can be designed to accommodate practically any pressure or capacity. => For this reason, the reciprocating compressor is the most common type found in the gas industry. Each compressor is designed to handle a specic range of volumes, pressures, and compression ratios.

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

Compared to the rotary compressor, the reciprocating compressor is more complex, and may cost more to maintain. However, its higher efciency and ability to handle greater pressures outweigh these disadvantages. Generally, small rotary compressors are driven by electric motors, while the larger rotary compressors are usually turbine driven. Reciprocating compressors may be driven by electric motors, turbines (gas or steam) or engines (gas or diesel). In some types of reciprocating compressors, the power cylinders and compression cylinders are integrated (tch hp) into one unit, and share the same frame and crankshaft. These compressors are referred to as integral units. The power and compression cylinders of an integral unit may be either horizontally opposed or in a Vconguration with the power cylinders on one bank and the compression cylinders on the other.
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THE OIL-FLOODED ROTARY SCREW COMPRESSOR Another type of reciprocating compressor is the separable unit. In this type unit, the prime mover is separate from the compressor, thereby allowing the user to choose the driver best suited to the application. Although this design may beslightly more complex than that of the integral unit, its inherent exibility often gives the separable unit an advantage over the integral unit. A wide variety of compressor designs can be used on the separable unit including horizontal, vertical, semi-radial and Vtype. However, the most common design is the horizontal, balanced-opposed compressor because of its stability and reduced vibration.

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR HELICAL ROTORS

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR The rotary screw compressor consists of two intermeshing helical rotors contained in a housing. Clearance between the rotor pair and between the housing and the rotors is .003 in to .005 in. The main rotor (male rotor) is driven through a shaft extension by an engine or electric motor. The other rotor (female rotor) is driven by the main rotor through the oil lm from the oil injection; there is no metal contact. The length and diameter of the rotors determine the capacity and the discharge pressure. The longer the rotors, the higher the pressure; the larger the diameter of the rotors, the greater the capacity. The helical rotor grooves are lled with gas as they pass the suction port. As the rotors turn, the grooves are closed by the housing walls, forming a compression chamber.
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THE OIL-FLOODED ROTARY SCREW COMPRESSOR ROTOR SCREW AIR COMPRESSOR PRINCIPLE

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR ROTOR SCREW AIR COMPRESSOR PRINCIPLE

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR ROTOR SCREW AIR COMPRESSOR PRINCIPLE

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR Lubricant is injected into the compression chamber after the grooves close to provide sealing , cooling and lubrication . As the rotors turn to compress the lubricant /gas mixture, the compression chamber volume decreases, compressing the gas/ lubricant toward the discharge port. The gas/ lubricant mixture exits from the compressor as the compression chamber passes the discharge port. Each rotor is supported by anti-friction bearings held in end plates near the ends of the rotor shaft. The bearings at one end, usually the discharge, x the rotor against axial thrust (lc dc trc) , carry radial (ly tm) loads, and provide for the small axial running clearances necessary.

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

TYPICAL LUBRICATION CIRCUIT OF A SCREW COMPRESSOR

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR After compression, the gas/ lubricant mixture enters a multistage separator which removes the lubricant from the gas. From the separator, the gas ows to the aftercooler The lubricant is also cooled, returning to the compressor through a thermostatically-controlled valve. Oil is the lifeblood of a rotary screw compressor. The limited clearance inside the rotary screw means that without proper lubrication, the screw may experience higher than normal wear (hao mn). Rotary screw compressor operators use a synthetic (tng hp) hy-drocarbon oil of ISO 100, 150 or 220 viscosity ( nht). Viscosity is selected based on the specic gravity of the gas. The gas analysis is very important in oil selection.

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR During the initial start-up (khi ng ban u) of a unit, gas will dilute (pha long, gim) the viscosity of the oil. It should not be allowed to drop below the minimum recommended value. Since the rotary screw has a closed oil system, it should use minimal oil. Most packagers design the package with oil carryover (cun theo) of ve (5) parts per million. If a rotary screw compressor loses oil and no leak can be found, then the oil is going down the sell line. These conditions mean a scavenging line orice is plugged (ng lm sch du b tc) or a coalescing lter has collapsed (bin dng).

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR The oil lter for the oil injected into the rotary screw is a 10micron lter. The ne mesh (l nh) is needed to protect the bearings and shaft seal. An oil change is recommended only every 8,000 operating hours, unless the oil is contaminated (nhim bn). A regular oil sampling will help the operator determine when an oil change is needed. Many rotary screw models are available with internal capacity control and variable volume ratio systems, which permit efcient variable load and pressure operation. Such systems are particularly desirable when constant speed electric motors are used and varying pressure conditions exist.

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

CAPACITY CONTROL SLIDE VALVE SCREW COMPRESSOR

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

ADVANTAGES OF THE ROTARY SCREW COMPRESSOR In many applications, the rotary screw compressor offers signicant advantages over reciprocating compressors: 1. Its few moving parts mean the elimination of maintenance items such as compressor valves, packing and piston rings, and the associated downtime for replacement. 2. The absence of reciprocating inertial forces (lc qun tnh) allows the compressor to run at high speeds, which results in more compact units. 3. The continuous ow of cooling lubricant permits much higher single-stage compression ratios. 4. The compactness (chc gn) tends to reduce package costs. 5. Rotary screw technology reduces or eliminates pulsations (s xung ng, va p), resulting in reduced vibration. 6. Higher speeds and compression ratios help to maximize available production horsepower.
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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

APPLICATIONS FOR THE ROTARY SCREW COMPRESSOR

A rotary screw compressor package is ideal for numerous compression applications including: 1. Fuel gas boosting 2. Casing head gas boosting 3. Vapor recovery 4. Landll and digester gas compression 5. Propane/butane refrigeration compression 6. Compression of corrosive (n mn) and/or dirty process gases

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR A rotary screw compressor package can also be used to upgrade existing reciprocating compressor installations. By boosting low suction pressure, capacity may be increased at minimum cost with continued use of existing reciprocating equipment. If an application requires large volume/ low suction pressure, but discharge pressures are greater than the screw can provide, a combination screw/ reciprocating unit with a common driver can be the solution

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR VAPOR RECOVERY One example of rotary screw utilization (ng dng) is for vapor recovery. Vapor recovery is the gathering of stock tank vapors and the compression of these vapors into the gas sales line. Capturing (thu hi) these vapors is protable and environmentally advisable. The gas vapors are gathered into a common header (hp phn phi) and fed into a vapor recovery unit (VRU), which usually includes a suction scrubber (b lc kh), a compressor, a driver, a discharge cooler and separator, and controls for unattended (ko gim st) operation. The vapors are usually rich and wet, conditions which lead to condensate and the washout (ra tri) of lubricant. Washout causes excessive wear (lm mn) in vanes or piston rings
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THE OIL-FLOODED ROTARY SCREW COMPRESSOR A rotary screw compressor does not suffer (gp phi) from these problems for two reasons: there is enough lubricant injected to take care of washout; and the rotary screw does not require the rotors to make contact with the stator. The sizing of a rotary screw compressor for vapor recovery is extremely(cc k) important. An oversized unit will operate in the partial load stage or shut down and start up too often . An undersized unit will not be able to keep up and the vents (l thot) will emit (pht) vapors into the atmosphere, defeating economy and the effort to maintain clean air.

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR SIZING (X/ K/T) A ROTARY SCREW COMPRESSOR To size a rotary screw compressor, one needs to know the suction and discharge pressures, the desired capacity, the gas analysis, temperature and the elevation. (See Eq. 1 for formula to determine capacity and Eq. 2 for formula to determine horse power.)

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR Figures 14.5A and 14.5B show adiabatic (on nhit) efciency at different pressure ratios,hile Fig. 14.6 shows efciency change with variable volume ratio.

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

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THE OIL-FLOODED ROTARY SCREW COMPRESSOR

THANK MUCH FOR YOUR ATTENTION

Q&A

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