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International Compressor Engineering Conference School of Mechanical Engineering
1986
J. L. Bowman
Singh, P. J. and Bowman, J. L., "Effect of Design Parameters on Oil-Flooded Screw Compressor Performance" (1986). International
Compressor Engineering Conference. Paper 517.
http://docs.lib.purdue.edu/icec/517
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ED SCREW
EFFECT OF DESIGN PARAMETERS ON OIL-FLOOD
COMPRESSOR PERFORMANCE
Pawan J. Sing h
INGERSOLL-RAND COMPANY
Phil lipsb urg, N.J.
Jame s L. Bowman
INGERSOLL-RAND COMPANY
Moc ksvi lle, N;C.
ABSTRACT
71
INTRODUCTION
Historically, oil-flooded rqtary screw air compressors
have been designed with certain standardized features
such as rotor profile and number of male-female rotor
lobe combinations. This was because the generation
of new profiles and adaptation of manufacturing
methods (including the need for new tooling) was a
time-consuming and expensive task. In recent times
the advent of computerized highly-flexible rotor man-
ufacturing techniques and the development of computer-
based design techniques have provided new freedom to
the compressor designer. The designer now has the
flexibility to adjust the design parameters to their
most optimum values for a specific application.
In order to exercise this freedom he must have an
economical means of predicting the effect of these
parametric changes on the compressor performance and
size.
In 1980 the authors' company developed several com-
puter programs to rapidly generate rotor profiles
along with their supporting data (1). These programs
have the flexibility of generating profiles with dif-
ferent shapes and number of lobes, and analyzing
their associated leakage lengths and areas as well as
inlet and discharge port shapes and sizes. These
data are then input to a performance prediction prog-
ram (2) to yield compressor BHP and capacity. These
programs can be used to conduct parametric studies of
the effect of geometrical clearances on compressor
performance for a known profile. Such studies have
been made by Singh and Patel (2) and Fugiwara et al
(3) who have provided a detailed accounting of the
flow and power losses as a function of clearances and
wrap angle.
This paper focuses on a more fundamental aspect of
the design process. A designer, using these advanced
techniques, can now select a certain profile shape,
and then for a given profile can select other par-
ameters such as number of male and female rotor
lobes, L/D ratio, wrap angle, discharge port opening
angle, etc. While these parameters have a great in-
fluence on the machine performance, strength and rel-
iability, meaningful data to guide the designer in
proper selection of these parameters does not exist
in the open literature. This paper fills this void
by presenting such data for typical screw compressor
applications and highlights the relative importance
of various parameters.
72
PROCEDURE
72a
This forces one to select larger female addendum
which generally results in a larger blow-hole. It
must be pointed out that we are talking about a
larger-blow- hole only in a relative sense. For ex-
ample, profile 3A has a blow-hole area of about .027
inZ for a 6 in diameter rotor while the comparable
area for profile 4 is only .003 in2. Also, the
importance of geometrical features such as blow-hole
area depends on the application. As the tip speed
increases, leakage areas begin to impact performance
less and less while inlet and discharge port areas
become more important. This is why integrated com-
puter tools such as those described in references 1
and 2 are so important for application- oriented
designs.
Table 2 lists the desired geometrical parameters that
affect compressor design and performance for various
profiles normalized to profile 4 values. The polar
moment of inertia is based on the female rotor root
diameter, Izfr = lT nfr/32, which serves as a
measure of the rotor's stiffness. The moment of
inertias of the complete male and female rotors about
their respective axis,
Izm 1 ( r2 (xdy-ydx)
4 Jm
lzf = 1 £ r2 (xdy-ydx)
4 jf
represent the stiffness of the rotor end profile in-
cluding lobes. In practice, however, the contribution
of lobes and the moment of inertia based on root dia-
meter is a good indicator of the rotor stifness.
From the table, it is apparent that profiles with
female-male lobe number difference (Nf-Nm) of 2
tend to have much stiffer female rotors than those
with Nr-Nm 1. This indicates that Nf-Nm
2 profiles may be preferable for high pressure
applications where rotor loads tend to be very high.
Table 2 also shows that the overlap constant, the
ratio of maximum filled volume to the theoretical
filled volume, is about the same for all profiles
except for the case of equal number of lobes. For
the 6-6 lobe profile, cavity fill volume is only
91.2\ of the theoretical volume which is also in-
dicated by early closing of the inlet port. Inlet
port closing angle decreases only slightly with the
increase in number of lobes except for the 6-6 case.
73
The angle "1!7 is defin~d as the angle of the leading
edge of the male cav1 ty and ranges from a negativ e
value at cavity' s incepti on to 8- max = 360 ( 1+1/N )
+SZ'm at cavity' s expirat ion. Unlike the inlet po~t
angle, the dischar ge port angle is a strong functio n
of the number of lobes. As Nm increas es, the dis-
charge port opens earlier as indicat ed by an increas e
in. the port _openin~ angle (common ly called 13m).
Th1s allows 1ncreas 1ngly large axial and radial
dischar ge ports with increas ing Nm-
The blow-ho le area for all the profile s is very small
by design except for profile 3A. The blow-ho le area
is a strong functio n of the female addendu m (outer
radius - pitch circle radius) which is about 1.5% for
most profile s except profile 3A for which it is 3\.
The selecti on of female addenqu m is not comple tely
arbitra ry since it strongl y affects the torque dis-
tributi on between the two rotors. Very small or neg-
ative addendu m can cause torque reversa l at certain
cavity positio ns, that may result in vibrati ons and
damage.
Table 2 also shows that the contact or interlo be
sealing length increas es strongl y with the number of
lobes which has an adverse effect on perform ance,
par~icularly at low-tip speeds and high pressur e
ratiOS. The maximum male and female rotor tip seal
leakage lengths also increas e slightl y with the num-
ber of lobes but the average leakage length over the
complet e cycle remains about the same. In fact, the
amount of tip seal leakage flow may actuall y decreas e
with number of lobes since the leakage has to pass
through more cavitie s before reachin g the inlet.
While it is instruc tive to examine how the selecti on
of number of lobes affects various geomet rical par-
ameters , the best compari son is obtaine d by examini ng
their perform ance charac teristic s under identic al
operati ng conditi ons. The next section address es the
effect of these parame ters on compres sor perform ance
and size.
PARAMETRIC EVALUATION
Effect of Number of Lobes on Airend Size.
Figure 2 shows the percent change in male & female
rotor cylinde r volume [ ~ (Dr+D~) ~ L/4 1
relativ e to profile 4 as a functio n of the number of
male rotor lobes. It is clear that smaller number of
lobes reduces rotor volume and thus the airend size.
74
Also, there is a distinct difference between
Nm-Nf ~ 2 and Nm-Nf = 1 profiles. The former
require considerably larger rotors for a given dis-
placement. This happens because, for a part of the
revolution, one of the female cavities is idling and
not taking part in the suction or compression process.
Effect of Number of Lobes on Rotor Stiffness
Rotor stiffness is an important parameter since it
may limit the maximum operating pressure of the com-
pressor. Figure 3 demonstrates the effect of number
of lobes on female rotor deflection based on root
diameter inertia lzfr· While stiffness is a strong
function of the selection of lobe depth, the profiles
with Nf-Nm = 2 have female rotors almost equal in
size to the male rotors and thus are inherently much
stiffer.
Effect of Number of Lobes on Discharge Port Velocity
The maximum gas velocity through the discharge port
is plotted in Figure No. 4 with the profile 4 taken
as the norm. This velocity is indicative of the port
losses that are proportional to velocity squared.
The plot shows that the velocity decreases with an
increase in the number of lobes. This is clear from
the trend in total discharge port area shown in table
2. It also means that the discharge port losses are
generally higher for profiles with less number of
lobes. Thus at high tip speeds where discharge port
losses become significant, profiles with a lower
number of lobes will have poor performance.
Effect of Lobe Combination on Performance
Figure 5 shows the volumetric efficiency (VE) and
normalized specific power (BHP/100 CFM) for various
profiles over a tip speed range of 10 to SOm/sec.
The performance is based on wrap angle~m = 300°,
L/D = 1.65, moderate clearances, typical oil in-
jection rates, inlet pressure = 14.5 psia, 7.8
pressure ratio, 7° early discharge port opening angle
and air as the compressed fluid. All profiles except
3A show specific power gradually increasing with tip
speed. The profile 3A which does not share the
common design philosophy of the rest has an optimum
performance at about 25m/sec. This is because at low
tip speeds, the large blow-hole area begins to
75
r-ca vity
adve rsely affe ct perfo rman ce throu gh inte r prof iles, the
leak age and reco mpre ssion . Amon g othe
wors t perfo rman ce at 50 m/se c
3-4 com bina tion has the .
due to its rest ricte d disc harg e port
marg inall y
Prof iles with lobe diffe renc e of 1 have renc es of 2
bett er perfo rman ce than thos e with diffe
show s the best
at all tip spee ds. Whil e prof ile 6-7iles with Nm ~
perfo rman ce in the diag ram, all prof
nt per-
5 to 7 can be cons idere d to have equi vale r from a prac -
form ance sinc e the diffe renc es are mino
with in the prog rams '
tica l poin t of view and are by now that the
accu racy . It shou ld also be clea r
a good prof ile
5-6 prof ile has all the attri bute s of size and thus
in term s of perfo rman ce, stren gth, and
aliza tion.
was sele cted as the base prof ile for enorm and othe r
It must be emph asize d agai n that thes
are vali d only for the nste d cond ition s and
resu lts only . For ex-
shou ld be used for rela tive purp oses 3-4 prof ile can
ampl e, high tip spee d perfo rman ce of the disc harg e
be impr oved cons idera bly by open ing
7° used here . Thus each
port even earl ier than the to the
desi gn shou ld be optim ized acco rding
indi vidu al appl icati on.
Effe ct of Wrap Angl e on Perfo rman ce
effe cts:
The chan ge in wrap angl e has two prim ary the over lap
The disc harg e port size incr ease s and
stan t decr ease s with wrap angl e. Tabl e 3 lists
con- cs of pro-
vario us impo rtant geom etric char acte ristito 400° .
file 4 for wrap angl e vary ing from 200°
ile 4 with L/D
Figu re 6 show s the perfo rman ce of prof angl es~- The
- 1.65 andtr;~ 7.8 at vario us wrap
perfo rman ce of the f'm ~ 200° desig n at high tip
poor ricti ve dis-
spee ds is agai n caus ed by over ly rest is indi cate d by
char ge port . The best perfo rman ce
angl e. It is inte rest ing that the gen-
300° wrap n also has the
eral ly poor perfo rmin g rr?m ~ 200° desig
VE whic h decr ease s with incr ease in wrap angl e.
best are smal ler at
This is beca use the leak age leng ths the limi t, one can
lowe r wrap angl es (tab le 3). In
~m = 0 whic h will then becom e a Root s com-
think of inte rlob e and
pres sor. In the Root s comp resso r,
al seal driv e leng ths are equa l to the roto r
radi
leng th but the buil t-in comp ressican on ratio is zero and
the axia l disc harg e port if one be conc eived is
extre mely smal l.
76
Effect of L/D Ratio on Performance
After the lobe combination, the next parameter
normally selected is the L/D ratio. The impact of
L/D ratio on airend performance for a 300° wrap
angle, 5-6 profile is plotted in Figure 1, while the
normalized geometric characteristics are listed in
Table 4. L/D ratio of 1.15 generally shows the worst
performance in figure 7 both for VE and specifice
power, particularly at the low tip speeds. A small
L/D ratio means larger diameter rotors for a given
displacement and larger leakage areas. At higher tip
speeds, the leakage areas begin to have less in-
fluence and performance for all L/D ratios tend to
cluster together. L/D ratios of 1.65 and 1.8 show
the best overall performance. It is perhaps no coin-
cidence that the commonly used values of wrap angle
of 300° and L/D = 1.65 based on experience also show
up so well in this study.
Effect of Opening The Discharge Port Early
One method of improving the performance is to open
the discharge port early, i.e., to reduce the
built-in pressure ratio. This has the effect of in-
creasing the discharge port size at the cost of some
backflow compression. However, at high tip speeds,
gas inertia tends to overcome this backflow effect
and significant improvement in performance can be
achieved. The optimum built-in pressure ratio and
other parameters such as opening angle is a function
of the profile shape, number of lobes, wrap angle and
L/D ratio. Figure 9a shows the effect of oo, 7° and
14° early opening on performance of the 5-6 profile.
The data indicates that specific power improves with
early opening at 50 m/sec while getting worse at
10m/sec. Even at 50m/sec it appears that any further
early opening will make the performance worse.
However, with 200° wrap angle, the effect on specific
power is significant even at 18.7° early opening
(Figure 9b) since the discharge port is very res-
trictive at the built-in pressure ratio as shown in
Table 3. Thus it is necessary to determine the op-
timum opening angle according to profile shape and
operating conditions.
77
CONCLUSIONS
in
Cons idera ble data relat ing the effec t of certa oil-
impo rtant param eters to the perfo rmanc e of
flood ed rotar y screw comp resso rs have been by pres-
data can be effec tivel y used a
ented . These of prope r
comp ressor desig ner as a guide in selec tion ing
param eters for a given appli catio n. The follow these data.
signi fican t concl usion s can be drawn from
(i) The numbe r of rotor lobes has a major stiffn influ ence
ess.
on comp ressor perfo rmanc e, size and rotor airen d but
Low numbe r of lobes can lead to a small er
e, parti cular ly at highe r tip
also poore r perfo rmanc inatio n
speed s and press ure ratio s. A 5-6 lobe comb unequ al
offer s a good overa ll desig n but leads to
on
rotor s. The best lobe numbe r selec tion depen dsd per-
the appli catio n and other consi d~rat ions beyon
forma nce such as ease of manu factu ring and main-
tenan ce of toler ances .
s of
(ii) A wrap angle of aroun d 300° and L/D ratio al air
1.5 to 1.9 offer good perfo rmanc e for typic
comp ressor appli catio ns.
the
(iii) Perfo rmanc e can be impro ved by openi ng openi ng is
disch arge port early . The amoun t of early
profi le and opera ting cond ition s.
a funct ion of rotor
(iv) The comp uter progr ams used here can be a
comp ressor geom etery ac-
powe rful aid in optim izing
cordi ng to the appli catio n.
ACKNOWLEDGEMENTS
78
TABLE 1
79
TABLE 2
TABLE 3
80
REFERENCES
SYMBOLS
N Number of lobes
D Outside diameter
Iz Polar moment of inertia
L Rotor length
r "' Profile radius
x,y profile coordinates in x,y plane
-e- Cavity position angle
l3 Discharge port opening angle
~ Wrap angle
1l'i Built-in pressure ratio
Integration around the profile
f
SUBSCRIPTS
m Male rotor
f Female rotor
fr "' Female rotor root diameter
81
5+6 Profile
7+6 Profile
82
,...._
~
30
<!)
~
.-I
0 20
i>
H
0
'-'
a 10
Cj
.....
<11
00
0 0
Q
"'
..c:: 0 Female Lobes Male Lobes +1
u
-10 a Female Lobes Male Lobes +2
l!. Female Lobes Male Lobes
-20
3 4 5 6
Number of Male Lobes
Cj
Female Lobes #Male L +1
.....0
'-' Female Lobes ftMale L +2
u
0) 20 Female Lobes f/Male L
.-I
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0)
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.,:
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.-I -20
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<11
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.....Q
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2u
3 4 5 6 7
Number of Male Lobes
83
.....0
.j..)
4
~ 0 Female Lobes "'
;., II Male Lobes +1
.j..)
..... 3 0 II Female Lobes "'
(J
0
r-1 II Male Lobes +2
Q)
>
.j..) 2
1--l
0
p.,
Q)
llO 1
1--l
.2(J
....."' !)
C1 3 4 5 6 7
Number of Male Lobes
84
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<.)
5
·...1
<.)
•...1
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4-<
P'l
l
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1
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o. 95
10 20 30 40 so
Male Rotor Tipspeed (m/sec)
85
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.,.,.......,
c.JiN:
tQ)
90
5
.-I
1.11
1.09
l.Ql
1.0
10 20 30 40 so
Male Rotor Tipspeed (m/sec)
86
"">-. 92
r..>
Q
<])
•rl
·rl
r..> -2.1'5
4-l
4-l 90 1.8
10<1
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!-<
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5
.-I
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86
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4-l....._ • 99
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o..u
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• 97
10 20 30 40 50
87
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u
0 00
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_,
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p.,
=
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0
p., 22
(.)
·.-!
......
·.-I
(.)
0!
21
0.
Vl
20
10 20 30 40 so
Male Rotor Tip speed (m/ sec)
(a) 70
26
s~
u
0
0 25 18.7°
......
..._
b:J
.....,
1'<1
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24
il)
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21
20 30 40· 50
Male Rotor Tip speed (m/s)
(b)
on
Figure 9 - Effect of Early Opening of Discharge Port
Specific Power for Profile 4.
(a) Wrap Angle - 3000.
(b) Wrap Angle - 200°.
88