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IMECE2013-62391
ABSTRACT
Screw compressors are complex flow systems, but operate INTRODUCTION
upon simple considerations: they are positive displacement
machines consisting of meshing rotors contained in a casing to Although the basic operation of twin screw compressors is
form a working chamber, whose volume depends only on the well known and the analytical methods for their performance
angle of rotation. Their performance is highly affected by prediction are well established, only few attempts of
leakages, which is dependent on various clearances and the investigating the flow in screw compressors by means of CFD
pressure differences across these clearances. Nowadays, the can be identified in the available literature. Nevertheless, there
manufacturing and profiling techniques have matured so much, are many advantages in considering CFD as integrated part of
that rotors of even the most complex shapes can be the design and optimization process of screw compressors (SC).
manufactured to tolerances in the order of few microns, This is mostly because CFD complements the experimental and
resulting in high efficiencies. With manufacturing tolerances analytical efforts by providing an alternative cost-effective
this tight, there is only small amount of improvement expected mean of simulating real fluid flows and substantially reduces
from further exploration of this venue, and a rather different lead times and costs of designs and production compared with
direction for analysis may be more rewarding, i.e. other an experimental based approach, Tiu and Liu [1]. Probably the
components of the screw compressor, like the suction and most noticeable efforts in the field of numerical analysis of SC
discharge areas. While the available literature includes several were made by Kovacevic et. al. [2] and [3], where in addition to
references on improvements of the compressor performance establishing a mesh procedure specific to such flow machines,
based on the analysis of the discharge port and discharge the author also explains adequate boundary calculations to
chamber, the investigation of the suction arrangement and inlet encourage good convergence and minimal numerical errors.
port remains fairly unexplored. This is the area of concern for Similar efforts were made by Sauls and Branch [4], where the
the present paper, where the influence of the port shape and commercial code ANSYS-CFX was used for the detailed
suction arrangement on the overall compressor performance is analysis of a refrigeration SC designed for use with R134a in
investigated. Various suction models were investigated for a air- and water-cooled chillers. Also benefiting from the mesh
standard screw compressor by means of CFD, which allowed technique documented in [2], Steinmann [5] reported results
in-depth analyses and flow visualizations, confirmed by the from the modeling of a helical-lobed pump and a SC using
experimental investigation carried out on the actual compressor. ANSYS-CFX. While the available literature includes several
Keywords: screw compressors, optimum suction, CFD references on improvements of the compressor performance
based on the analysis of the discharge port and discharge
0.20
Mass Flow [kg/sec]
In order to fully understand the flow mechanism in the The overall mesh statistics typically used for these compressor
suction area of the compressors and determine the reasons simulations are:
which influenced adversely the performance when opening a Main casing approx 82K nodes
radial port into the compression chamber, a numerical Discharge casing approx 86K
investigation was carried out. Inlet approx 176K nodes
An adaptive meshing technique is utilized to capture all the
Numerical mesh changes which occur within the working chamber during the
compression process.
The critical sub-domains in this setup are the two rotors as The number of time changes required by the rotors mesh is 120
they contain the working chamber as well as the clearances and for the full rotation of the male rotor, with the number of nodes
leakage paths (radial, axial, interlobe and blow-hole area). kept constant across the timesteps.
Generating the grids for these domains is by far the most
challenging part of the entire meshing procedure, as both micro- Boundary conditions
and macro- scales elements have to be solved (the interlobe
clearances are in the order of several microns, whilst the rest of The numerical model includes the stationary domain with
the rotor body measures over 1000 mm). In this case, a the major casing components (inlet, main and discharge) and
technique dedicated to screw compressor rotors was employed, the rotating domain, depicted by the two rotors, see Figure 5.
as described by Kovacević [3], which is included in SCORGgg Various interfaces were applied to each of these domains to
(Screw COmpressor Rotor Geometry grid generator). This ensure the flow transition between the different domains. All
procedure is fully explained in several publications included in these interfaces were considered to be General Grid Interfaces
the reference list (GGI). The original compressor model includes one interface
and therefore, will between the rotors and casing (called axial port, placed between
not be repeated the inlet casing the two rotors). The modified compressor
here. A simplified includes an additional interface to the rotors – the radial port
representation of machined in the main casing.
the rotors mesh
(cross-sectional
view) is presented
Power [kW]
Table 1 Boundary conditions
80
In all cases, oil injection was not simulated. 60 ORI-TEST
MOD-TEST
40
ORI-CFD
NUMERICAL RESULTS 20 MOD-CFD
0
The first step in the evaluation of the numerical results was
0 5 10 15 20 25
to compare the pressure levels in the two compressors, in order
to asses, from a compression point of view, the performance of PR [-]
the two models. For this purpose, a probe point was placed on
Figure 8 Power curves: numerical vs experimental
one grid node of the male rotor, on both the suction and
discharge faces and the total pressure was interrogated at each
time step, as shown in Figure 6 and Figure 7. It can be readily 0.20
observed that there is little to no difference in the variation of 0.16
Mass Flow [kg/sec]
Flow analysis in the suction casing Figure 10 Velocity vectors in the original compressor model
A detailed flow analysis was carried out for both
compressor models under each set of the investigated
parameters. For simplicity reasons, the visual analysis for
PR=10 will be presented next, though similar behaviour and
conclusions were drawn for the rest of the points in Table 1.
In a first attempt to understand the flow mechanism in the two
compressors models, the velocity vectors are plotted in the
overall numerical model depicted in Figure 5. The scale of the
plots starts at 0 m/s and has a maximum of 100 m/s. Figure 10
depicts the velocity vectors in the original compressor; from
suction (placed on the main casing) all the way to the axial port
(rotors interface between the rotors and the inlet casing), the
flow is steady and characterized by an average velocity of 6
m/s.
Figure 11 shows the same vector plot in the modified
compressor, keeping the scale magnitude. It can be readily
observed that the flow in this compressor is characterized by Figure 11 Velocity vectors in modified compressor model
two streams: one, the incoming flow from the suction to the
axial port; the second one (depicted in red because the vectors
are outwith the chosen scale) is highly disturbed flow coming
back into the main casing through the radial port. In this case,
the average velocity on the rotors interface (from the inlet
casing) is about 18 m/s.
In order to accentuate the differences between the flow paths in
the suction casing of the compressors, several snapshots of the
same velocity vectors, taken from different angles, are
presented next.
The still images are captured at the end of the rotation cycle, Figure 15 Velocity vectors in the modified suction casing
but are representative for any intermediate timestep after the (side view)
internal pressure build-up was achieved.
While Figure 12 and Figure 14 reveal no other interferences to Finally, Figure 16 and Figure 17 show contour plots of the
the main stream, the plots in Figure 13 and Figure 15 show the velocity on the axial port, both plotted on the same scale with a
highly disturbed flow field, where the main flow stream maximum at 20 m/s. While the original compressor is
encounters high-velocity flow returning from the radial characterized by a fairly uniform velocity distribution, which
interface with the rotors. Visually, it appears that the rotors act averages out at 6 m/s (as stated above), the axial port in the
as a resistance to the main stream, as part of the incoming flow modified compressor averages at 18 m/s and peaks with a
is redirected back into the suction area. This is due to the maximum of 33 m/s. This yields to a non-uniform high-velocity
atmospheric flow coming in direct contact with portions of the flow field at the interface with the rotors and is the main source
working chamber exposed to high pressure fields and sets the for increased leakages in the modified compressor and
scene for increasing gas leakages. The CFD simulation was therefore, causing the performance deterioration measured
experimentally and numerically.
CONCLUSIONS ACKNOWLEDGMENTS
The authors would like to thank the Centre for Positive
The shape of the suction port in a twin screw compressor is Displacement Machines for the continuous fruitful
often the subject of experimental investigations and the general collaboration. We also recognize the contribution of Howden
belief is that by opening the gas admission through a radial port Compressors Ltd in providing the environment in which work
at the suction will have a positive effect on the compressor such as this is supported.
performance, as more of the rotor area will be exposed to the
working gas.
In order to determine whether or not the inlet conditions bear an
effect on the overall compressor performance, two suction
scenarios were investigated for the same compressor, both
experimentally and numerically: one with axial port at the
compression chamber entry (referred to as original), the second
including the same axial port, as well as a radial port machined-
off from the inner casing wall (modified).
Tests on the compressor models did not reveal any
improvement in the modified casing and furthermore, for higher
pressure ratios, a slight deterioration in the performance of this
compressor was observed in terms of power and flow.
The CFD set-up delivered results well validated by the
experimental curves. The numerical predictions repeated the
trend of the experimental curves, i.e. no substantial difference
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