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Contents
1. Principle of operation and classification of the compressors .............................................. 2
2. Basic parameters of the compression process. Nature of the compression ......................... 4
3. Screw compressors .............................................................................................................. 6
3.1. Construction ................................................................................................................. 6
3.2. Fundamentals of operation........................................................................................... 7
3.3. Volume Ratio .............................................................................................................. 11
3.4. Capacity Control ......................................................................................................... 13
4. Methods for testing of screw compressors ......................................................................... 17
4.1. Testing of pressure distribution in twin screw compressors for multiphase
duties ................................................................................................................................. 17
4.2. Testing of screw refrigeration compressors under superfeed conditions ................... 19
4.3 Testing of gas screw compressors ( for natural gas or other types of gas ) ................. 23
5. Conclusion .......................................................................................................................... 26
6. Bibliography ....................................................................................................................... 27
pk
p2 .
p1
(1)
Similar concepts are introduced and the relationship of the volume and temperature
of the gas at the beginning and end of the process compression. If the volume of gas in the
trial ratio is V1 and at the end of the process is V2, then the relation V1/ V2 is called the
degree of compression and marked with
Vk
Vk
V2 .
V1
(2)
Tk
Tk
T2 .
T1
(3)
If in equation (1) the pressures p1 and p2 will be expressed from the equation of state
of ideal gas:
p.V = m.R.T,
(4)
and taking into account equations (2) and (2) for the rate of pressure rise is obtained [3]:
pk Vk . Tk
(5)
3. Screw compressors
Rotary screw compressors are widely used today in industrial refrigeration for
compression of ammonia and other refrigerating gases, petrol and gas industry or for
compressed air for industrial applications (and,function of final parameters and
compositions of gas screw compressors are two types : oil free and oil injected-floodedscrew compressors)
3.1. Construction
A typical oil flooded twin screw compressor consists of male and female rotors
mounted on bearings to fix their position in a rotor housing which holds the rotors in
closely toleranced intersecting cylindrical bores (figure 1).
Fig.5. Compression
3.2.3. Discharge Process
In the recip. compressor, the discharge process starts when the discharge valve first
opens. As the pressure in the cylinder exceeds the pressure above the valve, the valve
lifts, allowing the compressed gas to be pushed into the discharge manifold. The screw
compressor has no valves to determine when compression is over. The location of the
discharge ports determine when compression is over (figure 6).The volume of gas
remaining in the "V" shaped trapped pocket at discharge port opening is defined as the
volume at discharge, (Vd).
A radial discharge port is used on the outlet end of the slide valve and an axial port
is used on the discharge end wall. These two ports provide relief of the internal
compressed gas and allow it to be pushed into the discharge housing. Positioning of the
discharge ports is very important as this controls the amount of internal compression.
(6)
pi = Vik,
(7)
part load volume ratio correction like the first slide valves, thus part load efficiency is
comparable to slide valves that do not regulate the discharge port. Plug valves also tend
to be lower cost and simple in control method (figure 13).
superfeed condition. With the help of the simulation model and the experimental
recording of p-V diagrams, the effects of the process of superfeed with an economizer
on the compressors performance can be described clearly.
The working process of twin screw refrigeration compressors can be described by
mathematical models.
The geometrical parameters of the compressors can be calculated by computer
programs and the results can be input to the simulation program as functions of the male
rotor angle of rotation, such as volume curve, inlet port area, outlet port area, superfeed
port area, oil port area, slide valve by-pass port area, and all at-rest clearance areas
(contact line, rotor tips, cusp blow hole, and rotor end faces).
In the refrigeration systems, the capacity and COP can be improved by use of
economizer. On the other hand, the performance of twin screw compressors is affected by
the superfeed gas injection into compression chamber from the economizer. The onestage compression from suction to discharge in the compressor becomes the quasi-twostage compression. A superfeed process is added in the compression process originally.
The superfeed process in the control process of the compressor is shown in figure
16.
Due to the superfeed mid-pressure refrigerant gas injection into the compressor, the
refrigeration circle is changed, so the p-h diagram is changed as shown in figure 17.
4.3 Testing of gas screw compressors ( for natural gas or other types of gas )
4.3.1.Mechanical test
To conduct mechanical compressor test on bench mounted, whose configuration is
according Diagram of experimental stand
Mechanical test takes at least 4 hours at rated speed. If measurements are made at other
speeds, steps will be 10% of nnom and measurements will be made only after approx.15
min constant speed operation in order to stabilize the system (temperatures, vibration,
etc.)
During the test, the following requirements must be met:
-mechanical operation must be correct
-vibrations must be within their normal limits. The values recorded in sample report
-buyer and seller may require variation should be able to pressure / temperature / flow
within the limits specified in the operating manual.
minimum 4 hours.
Parameters are recorded during the test, measurements are presented in sheets
If replacement or modification of bearings or seals or dismantling of the case or
modify other parts is required to correct mechanical or performance deficiencies, the
initial test will not be acceptable, and the final shop test shall be run after these
deficiencies are corrected.
because the compressor internal losses occur, due to report pressure / pressure difference
across the rotor, which reduces the flow discharged (compared to the measured flow at
inlet)
b) power consumption for gas compression
There are several ways to measure power absorbed. Stand measurement function
facilities can be made by:
- Electronic torqmeter, between engine and compressor
- Double-watt meter method or equivalent method
With measured power consumption, can be calculated isentropic efficiency as the
ratio between theoretical isentropic power and measured power. Theoretical
Isentropic power is given by:
Pt, is = Gxk/k-1 xRxTaspx (
k-1/k
4. Conclusion
Rotary screw compressors are widely used today in industrial refrigeration because
of its inherent efficiency, safety, and flexibility.
The conditions in the refrigeration industry are changing and screw compressors are
also changing to meet customer's demands.
Modern machine tools and automated inspection equipment are making it possible to
hold tighter tolerances in day to day manufacturing environments. This improves
compressor performance and consistency from one compressor to the next.
The testing of the screw compressors is very important activity for checking of their
condition and work parameters. Therefore the improving of the compressor testing
methods is one of the ways for improving of the compressors.
6. Bibliography
[1] Feng Cao, Tieyu Gao, Songshan Li, Ziwen Xing, Pengcheng Shu. Experimental
analysis of pressure distribution in a twin screw compressor for multiphase duties.
Sciencedirect.com, 2010.
[2] Huagen Wu, Jianfeng Li, Ziwen Xing. Theoretical and experimental research on
the working process of screw refrigeration compressor under superfeed condition.
Sciencedirect.com, 2007.
[3] Grozev G., S. Stoyanov, G. Gujgulov. Hydro and pneumo machines and driving
installations. Sofia, 1990.
[4] Pillis J. W. Basics of Operation, Application & Troubleshooting of Screw
Compressors. 1998.
[5] API 619
[6] ISO 10440
[7] ISO 1217