SELF STUDY MATERIAL

ON
SCREW AIR COMPRESSOR

PREPAIRED BY: APPROVED BY:

NESAR ALAM

COMPRESSOR

ADHUNIK METALIKS LTD.

 CONTENTS

S.NO TOPIC PAZE

Introduction

Classification

Reciprocating compressor

Screw compressor

Features of screw compressor

Basic components of screw compressor

 COMPRESSORE
Compressors are a marching which raises the pressure of fluids
by pressing it in a closed vassal, for the use of various industrial
purposes.
There are many types of compressors and they
classified as follows.

Positive displacement compressor

In the positive-displacement type, a given quantity of air or
gas is trapped in a compression chamber and the volume it
occupies is mechanically reduced, causing a corresponding rise in
pressure prior to discharge. At constant speed, the air flow
remains essentially constant with variations in discharge pressure.

Dynamic compressor
• Dynamic compressors impart velocity energy to continuously
flowing air or gas by means of impellers rotating at very high
speeds. The velocity energy is changed into pressure energy both
by the impellers and the discharge volutes or diffusers. In the
centrifugal-type dynamic compressors, the shape of the impeller
blades determines the relationship between air flow and the
pressure (or head) generate

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Reciprocating compressor:

Reciprocating pump is just a reciprocal of IC engine. In IC engine

pressure developed in side cylinder piston due to combustion
heat, and this pressure pull piston which is connected with
crank shaft and crank shaft start rotating. In a reciprocating
compressor a prime mover rotate the crank shaft and piston
start reciprocating in cylinder. When piston go back (Suction
stroke) it suck air from spring loaded suction valve. When
piston goes forward (Compression stroke) spring loaded
discharge valve open and air discharged on discharge line, by
means of this continuous suction and compression stroke air
get compressing.

Advantages of reciprocating Compressor.

1. It has high compassion ratio
2. It has wide range of pressure and capacity
selections.
3. It has available in many configurations.
a. Air & water cooled
b. Lubricated and non lubricated
c. Single and double acting
d. Horizontal, & vertical

Disadvantages of reciprocating Compressor.

1. It has low discharge rate.
2. It has very noisy.
3. Maintenance cost is high.
4. Discharge Pr pulsation continuously.

Screw compressor
Compressors have rotors in place of pistons and give a
continuous pulsation free discharge. They operate at high
speed and generally provide higher throughput than
reciprocating compressors. Their capital costs are low, they
are compact in size, have low weight, and are easy to
maintain. For this reason they have gained popularity with
industry. They are most commonly used in sizes from about
30 to 200 hp or 22 to 150 kW.

Basic working principle of Screw compressor

• Figure 1 shows the basic geometry of the rotary screw

compressor. View (A) is a simple representation of the
actual rotors. We have labeled the male rotor lobe and the
female rotor flute. As the rotors turn in an outward
direction, the male flute will unmesh from the female flute
forming an area for the gas to enter. The gas becomes
trapped in the machine and compression occurs when the
lobes of the rotors begin to mesh together again. The
shaded area represents the pocket of gas that Occurs
within a specific flute. View (B) is a representation of the
side view of the machine. The same flute is shaded for
comparison. Here we see the suction port in the upper left
corner and the discharge port in the lower right corner.
The rotors will turn in an outward direction forcing the
male and female flutes to unmeshed, allowing process gas
to enter the top of the machine. The gas will travel around
 the outside of the rotors until it reaches the bottom where
the compression actually occurs. Gas will be discharged in
the lower right corner of the picture.

Discharge Suction

Mail rotor

Discharg
Suction
Female

(A) Rotors (B) Side View Rotary

 FEATURES OF THE SCREW COMPRESSOR
The rotary screw compressor is a positive displacement machine that
operates without the need for suction or discharge valves. It has the
ability to vary suction volume internally while reducing part load power
consumption. Screws provide a much wider operating range and lower
maintenance costs than conventional reciprocating machines. The
machines are much smaller and create much lower vibration levels than
piston machines as well.

Reduced Maintenance

The only significant moving parts in a screw compressor are the

male and female rotors. There are no valves, pistons, rings, or
connecting rods that require regular maintenance. With the elimination
of the pistons, rings and valves, annual maintenance costs are also
reduced on screw machines. It is not uncommon to operate screws for
several years without ever performing any significant maintenance
repairs. When comparing screw compressors and reciprocating
machines, it is important to consider maintenance costs into the overall
project cost.
Turn Down

Screw compressors offer turn down capabilities up to 90% of full

load with very good part load power requirements. This turn down
capability occurs within the machine and is independent of engine Speed
or bypass. This makes the machine an attractive alternative for areas
where flow rates and operating conditions are not constant. The capacity
control can typically be handled manually or automatically within the
machine to meet the exact demands of the overall system.

High Compression Ratios

Screw compressors can operate from roughly 2 to 20 ratios of

compression on a single stage while maintaining high volumetric
efficiencies. These efficiencies are achieved by injecting large
quantities of lube oil into the machine during the compression process.
Reciprocating machines can operate at much higher pressures than
screw machines, but are typically limited to roughly 4 ratios of
compression per stage.

Accommodates Wide Operating Ranges

The screw compressor itself can operate over a very wide range with
little or no changes required to the machine. This makes it very well
suited to the natural gas industry where flow rates and operating
conditions are often changing.

Smaller Package Sizes

Rotary screws provide high capacities with minimal installation space

compared to piston machines.
Lower Vibration

With only two major moving parts operating in a circular motion, screws
create much lower vibration levels than reciprocating machines.
Although the slide valve assembly also moves to control capacity, it
happens at such a slow rate that we do not consider it a maintenance
concern. With lower vibration levels, screw compressors do not require
the same type of foundation as the reciprocating machines, which can
result in lower installation costs. In general, screw compressors are
considered to provide very high reliability, resulting in lower
maintenance costs and reduced down time compared to reciprocating
machines.

Main components of Screw Air compressor

1. Air filter

2. Intake valve
3. Air end (Helical screw)

4. Receiver tank
5. Oil separator
 6. Minimum Pr valve
7. Pr relief valve
8. Oil filter
9. Thermal valve
10. Cooler
11. Moister separator
12. Cooling fan

Flow Diagram of a screw compressor

Moister filter
Service line

Moister drain line

Minimum
Pr valve Oil filter
Air filter

Air
cooler

Safety valve
Air intake valve
Oil separator element
Oil separator tank
Motor
Oil tank Air end

Cooling fan

Oil cooler Thermal valve

AIR LINE
s
Mixed oil & Air

Oil

Function of various systems and component

1. Air intake system

Air inlet system has a paper type dry filter, which filter the intake
air and prevent foreign partials from entering the air end.

2. Air intake valve

 This is a butter fly type valve fitted at top of air intake port, and
controls the intake air amount as per capacity and control, of
system requirement.

3. Air End.
Air end is the heart of compressor. It consists of two screw male
and female rotors & suction and discharge port. It is the part
where compression action takes place.

Suction port

Screw

Discharge port

Drive
Shaft
4. Receiver tank
Receiver tank received oil and air mixture discharged from air end
where oil and air are separated through oil separate.

5. Oil separator
Oil separator is a filtering element which separates the oil from oil
and air mixture,

6. Minimum Pr valve
Minimum pressure valve is non return type valve fitted at the end
of the separator tank , this valve ensures a minimum receiver
pressure of 4 bar during all conditions for proper oil separation
and proper oil circulation to the air end.

7. Pr relief valve

This valve is fitted on separate tank, it is spring loaded safety

valves and it is operate when thank pressure exceeds 2 bar more
than maximum working pressure.

8. Oil filter

It may be Paper or mesh type oil filter, to filter the system

circulating oil.
9. Thermal valve

The thermal valve is fitted in oil line as shown in fig.oil

temperature get rise due to compassion heat as the temperature
rise thermal valve start closing and is fully closed at 155F. And
the oil through the oil tank, oil filter to air end diverted through,
oil tank, oil cooler, oil filter & air end.

CONTROL ELEMENTS

1. Discharge temperature sensor

It is fitted in the air end discharge line to sense the air end
discharge temperature of air and oil mixture and set go give
warning message.
2. Pressure switch
Pressure switch is fitted on intake valve mourning adapter to
ensure the compressor switched off in case of reverse
rotation of compressor.
3. Pressure sensor
Pressure sensor is fitted on discharge line, it gives a signal to
activate blow- down solenoid valve and so the un load
automatically based on pressure seating in microcontroller.
4. Solenoid valve
 Solenoid valve is fitted on through the separator tank with
blow down and in take valve acctutor. This valve operates
on pressure signal, and with it blow down and intake valve
also operates.
5. Blow down valve
This valve operates on pressure signal, and with it solenoid
valve and intake valve also and reduce sump pr below 2 Bar.

OPERATING MODES

1. Start mode
When the compressor is turn On the solenoid valve activated
the blow down valve for a set time this reduce the load on
motor on starting , this time set till star to delta takes place in
motor starting circuit.
2. On load mode (Normal operating mode.)
In this mode solenoid valve de activated and blow down valve
close and intake valve opens and compressor start normal
working.
3. Un load mode
When the pressure sensor sense the higher pressure set on
controller, controller operates solenoid valve, and so blown
 down valve operates and intake valve close. In this mode
compressor running but not making pressure.
4. Standby Mode
When compressor running continue in unload mode more the
set time in controller, compressor step running,(motor
stopped) and automatically start when pr get down below
minimum set level.

Maintenance of Screw compressor