3

Calculation of Screw Compressor Performance

Screw compressor performance is governed by the interactive effects of ther-

modynamic and fluid flow processes and the machine geometry and thus can
be calculated reliably only by their simultaneous consideration. This may be
achieved by mathematical modelling in one or more dimensions. For most ap-
plications, a one dimensional model is sufficient and this is described in full.
3-D modelling is more complex and is presented here only in outline. A more
detailed presentation of this will be made in a separate publication.

3.1 One Dimensional Mathematical Model

The algorithm used to describe the thermodynamic and fluid flow processes in
a screw compressor is based on a mathematical model. This defines the instan-
taneous volume of the working chamber and its change with rotational angle
or time, to which the conservation equations of energy and mass continuity are
applied, together with a set of algebraic relationships used to define various
phenomena related to the suction, compression and discharge of the working
fluid. These form a set of simultaneous non-linear differential equations which
cannot be solved in closed form.
The solution of the equation set is performed numerically by means of
the Runge-Kutta 4th order method, with appropriate initial and boundary
conditions.
The model accounts for a number of “real-life” effects, which may signifi-
cantly influence the performance of a real compressor. These make it suitable
for a wide range of applications and include the following:
– The working fluid compressed can be any gas or liquid-gas mixture for which
an equation of state and internal energy-enthalpy relation is known, i.e. any
ideal or real gas or liquid-gas mixture of known properties.
– The model accounts for heat transfer between the gas and the compressor
rotors or its casing in a form, which though approximate, reproduces the
overall effect to a good first order level of accuracy.
50 3 Calculation of Screw Compressor Performance

– The model accounts for leakage of the working medium through the clear-
ances between the two rotors and between the rotors and the stationary
parts of the compressor.
– The process equations and the subroutines for their solution are indepen-
dent of those which define the compressor geometry. Hence, the model can
be readily adapted to estimate the performance of any geometry or type of
positive displacement machine.
– The effects of liquid injection, including that of oil, water, or refrigerant can
be accounted for during the suction, compression and discharge stages.
– A set of subroutines to estimate the thermodynamic properties and changes
of state of the working fluid during the entire compressor cycle of operations
completes the equation set and thereby enables it to be solved.

Certain assumptions had to be introduced to ensure efficient computa-

tion. These do not impose any limitations on the model nor cause significant
departures from the real processes and are as follows:

– The fluid flow in the model is assumed to be quasi one-dimensional

– Kinetic energy changes of the working fluid within the working chamber are
negligible compared to internal energy changes.
– Gas or gas-liquid inflow to and outflow from the compressor ports is assumed
to be isentropic.
– Leakage flow of the fluid through the clearances is assumed to be adiabatic.

3.1.1 Conservation Equations

for Control Volume and Auxiliary Relationships

The working chamber of a screw machine is the space within it that contains
the working fluid. This is a typical example of an open thermodynamic system
in which the mass flow varies with time. This, as well as the suction and dis-
charge plenums, can be defined by a control volume for which the differential
equations of the conservation laws for energy and mass are written. These are
derived in Appendix B, using Reynolds Transport Theorem.
A feature of the model is the use of the non-steady flow energy equation to
compute the thermodynamic and flow processes in a screw machine in terms
of rotational angle or time and how these are affected by rotor profile modi-
fications. Internal energy, rather than enthalpy, is then the derived variable.
This is computationally more convenient than using enthalpy as the derived
variable since, even in the case of real fluids, it may be derived, without refer-
ence to pressure. Computation is then carried out through a series of iterative
cycles until the solution converges. Pressure, which is the desired output vari-
able, can then be derived directly from it, together with the remaining required
thermodynamic properties.
The following forms of the conservation equations have been employed in
the model: