Screw Compressor

Modelling, Design and Use

Screw Compressor Basics
Professor N. Stosic
Chair in Positive Displacement Compressor Technology
Centre for
Positive Displacement Compressor Technology
City University London, U.K.
Screw Compressor Today
Highly competitive market, specially
in air compression and refrigeration
Continuous improvement:
more compact, efficient and
cost effective compressors
New rotor generation, rotors optimized
for certain compressor duty, specialized
design
Scope for innovation,
improvement and development
INTRODUCTION
INTRODUCTION
Basics
View from Front and Top
View from Bottom and Rear
Top and front: Admission
Bottom: Change of volume
Bottom and Rear: Discharge
INTRODUCTION
Basics
INTRODUCTION
Swedish company SRM, pioneer and leader
Screw compressor profiles, Symmetric,
Asymmetric, D and G
Screw compressor design
Screw compressor technology
Licence system left many screw compressor
manufacturers at margins of research and
development
INTRODUCTION
Many companies started their own development
Gardner Denver, Atlas Copco, Compair, Kaeser, GHH
Trane, Ingersol-Rand, Hitachi, Fu Sheng, Hanbel, Refcomp
Holroyd
Many more or less successful rotor profiles
Many more or less successful screw compressor designs
Need exists to concentrate efforts in R&D
Centre for Positive Displacement
Compressor Technology
Improved methods of analysis
Experimental validation
Design of critical components
Complete machine design
Product development
Training in machine design
INTRODUCTION
Methods Applied
Advanced Computerized design tools
Machine process modelling
2-D and 3-D Computational Fluid Dynamics
Modern experimental technique
Computerized data acquisition
Users
Renown and new companies,
large and small manufacturers
in the U.K and abroad
INTRODUCTION
SCREW COMPRRESSOR GEOMETRY
Before modelling the physical process, the rotor lobe profiles
must be defined together with the remaining parameters with
which the rotor and housing geometry can be fully specified.
Rotor profile: x and y coordinates, pressure angle
Helix/lead angle, rotor length
Interlobe, end and radial clearance
Suction/discharge ports
SCREW COMPRESSOR GEOMETRY
General case: non-parallel and non-intersecting
( ) [ ] [ ]
1 1 1 1 1 01 01 01 01 1
, , , cos sin , sin cos , t x y z x y x y p + r r
1
]
1

1
]
1

0 , cos sin , sin cos 0 , ,

01 01 01 01 1 1 1

t
y
t
x
t
y
t
x
t
y
t
x
t
r
[ ] 0 , , 0 , ,
01 01
1 1 1
x y
y x

1
]
1

r
Given profile
SCREW COMPRESSOR GEOMETRY
Meshing condition
Meshed profile
General case: non-parallel and non-intersecting
( ) [ ] [ ]
[ ]
2 2 2 2 2 1 1 1 1 1
02 02 02 02 2
, , , , , cos sin , sin cos
cos sin , sin cos ,
t x y z x C y z y z
x y x y p


+
+
r r
[ ] [ ]
( ) ( )
2
2 2 2 02 02 02 02 2
1 1 2 1 2 1
, , sin cos , cos sin ,
sin cos , sin cos , cos sin
y x p x y x y p
p y p x C p x C

+ 1
]
r
1 1 1 1 1 2
0
t t

_ _



, ,
r r r r r r
( ) ( )
1 1 1 1
1 1 2 1 1 1 1 2
cot cot 0
x y y x
C x p p x y p p p C
t t t t

_ 1
+ + + + 1
] 1

, ]
SCREW COMPRESSOR GEOMETRY
General case: non-parallel and non-intersecting
corresponds to the rotor hobbing tool relation
Special cases:
p
2
=0, rotor - plate milling tool, grinding tool relation
=0, screw compressor rotors
SCREW COMPRESSOR GEOMETRY
01
01 01
01
sin cos 0
dy C C
ky kx
dx i i

_
+ +

,
02 01 01
02 01 01
cos sin cos
sin cos sin
x x k y k C
i
y x k y k C
i

+ +
Meshing condition
Rotor profile, =0, i=p2/p1, k=1-1/i
Meshed profile
Rack profile
0 01 01
0 01 01 1
cos sin
sin cos
r
r
x x y
y x y r



+
Numerical solution of the meshing condition
Task: to find for a zero function
Simple iteration method:
Fast and reliable, but valid only for certain function
Additional complication
In certain areas two or more are the zero function
Only one is valid, additional values found by half
interval method
SCREW COMPRESSOR GEOMETRY
Demonstrator profile
N ROTOR PROFILE
- Rack generation procedure
- Straight line on the rack - involute rotor contact
- Small torque transmitted
- Short sealing line
- Large displacement
- Strong gate rotor,
SCREW COMPRESSOR GEOMETRY
SCREW COMPRRESSOR THERMODYNAMICS
Differential approach:
Set of differential equations solved simultaneously
Equations of continuity, momentum and energy
Preintegrated equations inadequate and inaccurate
if high leakage rate and heat transfer is involved
in in out out
dU dV
m h m h Q p
d d


+ ! !
in out
dm
m m
d

! !
2 2
2 1
2
2
1
2ln
l l l g g
p p
m w A A
p
a
p

_
+

,
!
Internal Energy
Continuity
Leakage Flow
, , in in suc suc l g l g oil oil
m h m h m h m h + + ! ! ! !
, , out out dis dis l l l l
m h m h m h +
! ! !
, in suc l g oil
m m m m + +
! ! ! !
, out dis l l
m m m + ! ! ! m wA
!
SCREW COMPRESSOR THERMODYNAMICS
Momentum
2
0
2
l
l l
g
w dp dx
w dw f
D
+ +
SCREW COMPRESSOR THERMODYNAMICS
Ideal Gas
( )
1
u RT
T p
R v

Real gas
p=f
1
(T,v) u=f
2
(T,v)
Wet vapour
( ) ( )
1 1
f g f g
u x u xu v x v xv + +
( ), ( ), ( ), ,
V
U m V v
m

( )
o o oil
oil
oil oil
h A T T
dT
d m c

,
1
oil p
oil
T kT
T
k

+
6
oil oil S oil
o o o
m c d c
k
h A h




( ) ( )
,
oil
U mu mu +
Oil injection
Numerical solution, Runge-Kutta IV order solver
( )
oil
U mcT
u
m

SCREW COMPRESSOR THERMODYNAMICS

Compressor integral parameters
in out
m m m
1
/ 60 m mz n
!
0
60 / V m
!
( )
1 2 1
60
n n
t
F F Lnz
m
+
!
v
t
m
m

!
!
ind
cycle
W Vdp

1
60
ind
ind
W z n
P
sind
cycle
V
W dp
m

t a
t a
ind ind
W W
W W

( )
2
1 2 1
1
ln
1
t a
p
W RT W R T T
p

sin d
P
P
V

!
SCREW COMPRESSOR THERMODYNAMICS
Calculation of pressure loads
On compressor rotors
Radial forces
( )
( )
B
x B A
A
B
y B A
A
R p dy p y y
R p dx p x x

Rotor torque
( )
2 2 2 2
0.5
B B
B A B A
A A
T p xdx p ydy p x x y y + +

SCREW COMPRESSOR THERMODYNAMICS
Bearing reactions and
rotor deflections
2
2
d M
EI dz

Optimization variables and target function

Single stage:
Rotor variables:
r
0
Female rotor addendum
r
1
Male rotor lobe radius
r
2
Male rotor tip radius
r
3
Female rotor tip radius
Compressor variables:
Built-in volume ratio
Operation variables:
Shaft speed
Oil flow
Injection position
Oil temperature
9 Variables
Multistage:
9 Variables x Number of stages
+ Interstage pressures
Target function:
Specific power combined
with compressor price
F=w
1
L+w
2
C
SCREW COMPRESSOR OPTIMIZATION
Box constrained simplex method for efficient and reliable
multivariable optimization
1 2
( , ,..., )
n
f x x x
, 1,
i i i
g x h i n , 1,
i i i
g y h i n m + y
n+1
,,y
m
1 2
F w L w C +
1 2
1 2
( ) max ( ), ( ),..., ( )
( ) min ( ), ( ),..., ( )
h k
g k
f x f x f x f x
f x f x f x f x

1
1
,
1
k
i i l
j
i
x x x x
k

( )
r l
x x x x +
( ) ( )
0.5 (1 ) ( )(1 )(2 1)
r new r old h h
x x cx c x x x c R
1 + + +
]
1
1
r r
r
n k
n
r
r r
n
c
n k
+
_

+
,
Dry Oil-Flooded Refrig.
r
0
[mm] 2.62 0.74 0.83
r
1
[mm] 19.9 17.8 19.3
r
2
[mm] 6.9 5.3 4.5
r
3
[mm] 11.2 5.5 5.2
Built-in volume ratio 1.83 4.1 3.7
Rotor speed [rpm] 7560 3690 3570
Oil flow [lit/min] - 12 8
Injection position [
o
] - 65 61
Oil temperature [
o
] - 33 32
Oil Free
Oil Flooded
Refrigeration
EXAMPLE OF CALCULATION
5-6-128 mm Oil-Flooded Air Compressor
7 m
3
/min, max 10 m
3
/min at 8 bar (abs)
5-14 bar (abs), max 15 bar (max)
EXAMPLES OF CALCULATION
5/6-128 mm, L/D 1.65
Displacement 1.56 l/rev
Interlobe sealing line 0.13 m
Blow-hole area 1.85 mm
2
Rotors optimized for
oil flooded operated
air compression
EXAMPLES OF CALCULATION
CAD Interface: Compressor ports
EXAMPLES OF CALCULATION
Experimental verification of the model
EXAMPLES OF CALCULATION
Compressor in the test bed
EXAMPLES OF CALCULATION
Comparison of the
calculated and test
results Flow-Power
EXAMPLES OF CALCULATION
EXAMPLES OF 3-D CFD CALCULATION
Majority of design problems can be solved by the
one-dimensional approach, some of them require the
two dimensional calculation, however, there are
situations where 3-D CFD must be applied
Such are
Oil flow distribution,
Fluid-Solid Interaction
Grid topology
- polyhedral
- O - grid
- H - grid
- C - grid
Cell shape
Grid generation
Grid generation
-
-
1
1
Grid generation - 2
- Male rotor - Female rotor
- Suction port - Discharge port
- Suction and discharge receivers
- End clearances
Rotor connections, clearances,
leakage paths
Grid topology strongly affects accuracy, efficiency and ease of calculation
Full structured block generated hexahedral 3D-O mesh
Screw compressor sub-domains:
Automatic discretization iscretization process: process:
- The rack generating procedure
- - Rack Rack - - a rotor with an infinite radius a rotor with an infinite radius
- - Divides working domain in two parts Divides working domain in two parts
male and female rotor, male and female rotor,
Screw Compressor FSI calculations
Screw Compressor FSI calculations
Comet
Comet
Mathematical model for screw compressor is based on conservation Mathematical model for screw compressor is based on conservation laws laws
of continuity, momentum, energy, concentration and space: of continuity, momentum, energy, concentration and space:
s
( ) 0
V S
d
dV d
dt
+

v v s
s
( )
b
V S S V
d
dV d d dV
dt
+ +

v v v v s T s f
s
s
( ) +
( grad : grad ) p
h
V S S
h
V V S V
d
hdV h d d
dt
d
s dV p dV d pdV
dt
+
+ + +


v v s = q s
v S v v s
s
( )
o o
o o c c
V S S V
d
c dV c d d S dV
dt
+ +

v v s q s
2
2 div
3
p T D vI I
!
o
c
grad
o o
D c q
h
grad T q
( , ), ( , ) p T e e p T
s
0
V S
d
dV d
dt


v s
s
2
s 1 2 3
( ) ( ) ,
( ) ( )
k
V S S V
V S S V
d
kdV k d d P dV
dt
d
dV d d C P C C dV
dt k k

+ +
+ + +


v v s q s
v v s q s v
Closed by constitutive relations and equation of state Closed by constitutive relations and equation of state
and accompanied by turbulence model. and accompanied by turbulence model.
( ) ( )
2 div
3 2
r
T T



+
T D+ wI
I
Thermodynamic properties of real fluids
Thermodynamic properties of real fluids
- - p p- -v v- -T T equation equation
compressibility factor compressibility factor z z
- - z z is assumed to change linearly is assumed to change linearly
with pressure err<2% with pressure err<2%
- - Antoine equation for saturation Antoine equation for saturation
temperature temperature
- - Clapeyron Clapeyron equation for latent heat equation for latent heat
- - Specific heat for constant pressure Specific heat for constant pressure
- - Density of mixture Density of mixture
- - Coefficient in the pressure correction Coefficient in the pressure correction
equation equation
( )
p
z RT z p RT

1 2
z p B B +
1
1
v v
T
b d
C
dp zRT z

_
_


,
,
2
1
log
sat
A
T
A p

2 3
0 1 2 3 pv
c C C T C T C T + + +
1 1
sat
L
v l sat
dP
h T
dT
_


,
2 2
1
1
v l
co co

Multiphase flow
Multiphase flow
( )
o o o o
o ol con mass
d m h dh dm
m h Q Q
dt dt dt
+ +
! !
- - Oil Oil
is assumed to be a passive is assumed to be a passive species species
- - Mass calculated from the concentration Mass calculated from the concentration
Oil drag force influence concentration Oil drag force influence concentration
- - Energy source due to heat transfer Energy source due to heat transfer
between working fluid and oil is: between working fluid and oil is:
s
ol ol L
mass L L L L
m m dm
Q h h h m
dt t

!
!
1
o o
k k
con o p o p
dT T T
Q m C m C
dt t

!
( )
pm s
L
L
m C T T
m
h

!
1
(
2
drag o drag o o
A C f v v v v)
- - Liquid phase Liquid phase
is assumed to be an active is assumed to be an active species species
- - Mass source Mass source
evaporated/condensed mass evaporated/condensed mass
- - Energy source Energy source
energy of evaporation/condensation energy of evaporation/condensation
o o
m m C
Euler Euler- -Lagrange approach Lagrange approach
Boundary conditions
Boundary conditions
- - Wall boundaries with wall functions are Wall boundaries with wall functions are
introduced on the housing and rotors. introduced on the housing and rotors.
const
add
p const const
p p dm V
m
dt p t

_


,
!
add
add add add add
p const
dm
Q h m h
dt

_


,
!
!
!
- - Compressor positioned between suction Compressor positioned between suction
and discharge receivers of small volume and discharge receivers of small volume
- - Inlet & outlet receivers and oil port are Inlet & outlet receivers and oil port are
treated as boundary domains: treated as boundary domains:
- - Mass equation corrected by mass Mass equation corrected by mass
source to maintain constant pressure source to maintain constant pressure
- - Energy equation corrected by energy Energy equation corrected by energy
source to update energy balance source to update energy balance
Screw Compressor performance
Screw Compressor performance
- - Volume flow (inlet and outlet) Volume flow (inlet and outlet)
- - Mass flow (inlet, outlet and oil) Mass flow (inlet, outlet and oil)
- - Boundary forces Boundary forces
- - Restraint Forces and Torque Restraint Forces and Torque
- - Compressor shaft power Compressor shaft power
- - Specific power Specific power
- - Efficiency Efficiency
Volumetric and adiabatic Volumetric and adiabatic
( ) ( )
3
1
60 min ,
end
start
t
I
t t
f f fi fi
t t i
V V m V v S

1
]

! ! !
[ ]
( )
( )
sec
end
start
t
t
t
f
t t
m V kg

!
!
* ; * ; *
x b xb y b yb z b zb
F p A F p A F p A
1 1
1 1
( ),[ ]; ( ), [ ]
( ),[ ]; ( ), [ ]
I I
rS rS rD rD
i i
I I
a a
i i
F F i N F F i N
F F i N T T i Nm






2 ( ) [ ]
M F
P n T T W +
3
min 1000
spec
kW P
P
m V
1

1
]
!
;
ad
v i
d
P
V
V P

!
Oil injected
Oil injected
-
-
Pressure in axial section
Pressure in axial section
Oil injected
Oil injected
-
-
Pressure and velocity
Pressure and velocity
Oil injected
Oil injected
-
-
Pressure 3D view
Pressure 3D view
Real fluid
Real fluid
-
-
Ammonia
Ammonia

pressure
pressure
Experimental verification
Experimental verification

P
P
-
-

diagram
diagram
Oil injected
Oil injected

Deformation
Deformation
Pressure1
Pressure1
P
inl
=1 b P
out
=7 b n=5000 rpm
t
inl
=20
o
C t
out
=40
o
C
P
inl
=1 b P
out
=7 b n=5000 rpm
t
inl
=20
o
C t
out
=40
o
C
Oil injected
Oil injected

Deformation
Deformation
Pressure
Pressure
-
-
1
1
P
inl
=1 b P
out
=7 b n=5000 rpm
t
inl
=20
o
C t
out
=40
o
C mag=20,000x
Oil injected
Oil injected

Deformation
Deformation
Pressure
Pressure
-
-
2
2
Oil injected
Oil injected

Deformation
Deformation
Temperature
Temperature
P
inl
=1 b P
out
=3 b n=5000 rpm
t
inl
=20
o
C t
out
=150
o
C mag=1,000x
Oil injected
Oil injected

Deformation
Deformation
Pressure+Temperature
Pressure+Temperature
P
inl
=30 b P
out
=90 b n=5000 rpm
t
inl
=0
o
C t
out
=40
o
C mag=2,000x
DESIGN EXAMPLES
Oil-free air compressor
Oil-flooded air compressor
Retrofit rotors of an air compressor
Refrigeration compressor
Compressors for Oil-Free
Air Delivery
Design aims:
Delivery: 350-700 and 700-1000 m
3
/h
Working pressure: 1-2.5 (2.7) bar
Volumetric efficiency 90 % +
Low specific power
Simple, reliable and compact machine
DESIGN EXAMPLES
3/5 lobe rotors
Large displacement
Convenient gear ratio 5/3=1.67
DESIGN EXAMPLES
Features of 3/5 N Rotors
- Highest possible displacement
- Higher delivery
- Better volumetric efficiency
- Better adiabatic efficiency
- Stronger gate rotor
- Long durability
- High reliability
- Easy manufacturing
- Easy compressor assembly
- Reasonable noise
DESIGN EXAMPLES
General Arrangement
XK18 Screw Compressor
DESIGN EXAMPLES
New design, fully
customized by the
manufacturer
New rotors,
New, improved
compressor
New concept, better screw compressor compared with competition
DESIGN EXAMPLES
Comparison of Test Results
R1- GHH C80
R2- Drum D9000
R3- Mouvex Typhoon
R4- GHH CS-1000
DESIGN EXAMPLES
Screw Compressor Family
for Oil-Flooded Operation
Design aims:
Delivery: 0.6-60 m
3
/min
Working pressure: 5-13 bar
Volumetric efficiency 90 % +
Low specific power
Simple, reliable and compact machine
DESIGN EXAMPLES
Improved capacity and efficiency
Lower power consumption
Reduced manufacturing cost
Reasonable efficiency for
moderate pressure ratios, at least the
same as for 4/6 rotors
4/5 Rotors
DESIGN EXAMPLES
Five compressors, rotor diameters:
74, 102, 159, 225 and 285 mm, L/D 1.55
Performance of the Compressor Family
DESIGN EXAMPLES
Proven design,
fully customized
to the the
manufacturers
needs
New rotors,
New, improved
compressor
DESIGN EXAMPLES
Test Results, Compressors 73 and 159 mm
DESIGN EXAMPLES
Retrofit N Rotors
5.4 % more displacement
6.5 % higher delivery
4 % better volumetric efficiency
2.5 % better adiabatic efficiency
75 % less torque on the gate rotor
DESIGN EXAMPLES
N Rotor retrofit
for more efficient
screw compressors
Asymmetric Rotors,
the most common
screw compressor
rotors
DESIGN EXAMPLES
Design of a semihermetic compressor
for air-conditioning and refrigeration
based on N rotors
Semihermetic, convertible to open
All existing refrigerants
Modern, better than competition
5/6-102 mm L/D=1.55
Efficient rotors for air condition and
refrigeration
DESIGN EXAMPLES
5/6-102 mm L/D=1.55 compressor
Theoretical displacement 0.72 l/rev
Gear-box 1500-10000 rpm
Delivery 0.920-5.80 m
3
/min
R-22
Air condition 5/40
o
C 60-380 kW
COP 4.20 at 3000 rpm
Refrigeration -5/30
o
C 33-210 kW
COP 3.95 at 3000 rpm
DESIGN EXAMPLES
Refrigeration Application
DESIGN EXAMPLES
Application of Design Optimization: A Family of Two-Stage Compressors
1
st
2
nd
Range: 22-250 kW
8-16 bar (abs)
Two-stages: 19 Variables
Target Function:
Minimum specific power
And only specific power
Number of frames
VFD vs gearbox
Stage size
Stage speed
Stage rotor profile
CONCLUSIONS
The screw compressor is a mature product at the millenium
meeting point. Orchestrated efforts of a large number of
companies driven by market forces resulted in the compact
and efficient compressor machine. Every detail counts
today. A small difference will give a small, but distinctive
improvement which may be used as an individual
advantage.
Optimization opens hidden spots still left for better
compressors. They result in stronger but lighter rotors with
higher displacement, more compact and more efficient
compressor machines at all areas of their application.
EPILOGUE
The Centre for Positive Displacement Compressor
Technology carries out research and provide a service to
manufacturing companies in all aspects of compressor
design and development. Through the everyday activity
the Centre is gaining experience in the compressor
research, development and design. Some of the recent
experience is given in this presentation.