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PER Microproject

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

GOVERNMENT POLYTECHNIC, JALGAON


(0018)

Program Name and Code : ME 5I (A)


Course Name and Code : PER (22562)
Academic Year : 2023-24
Semester : Fifth

A MICRO PROJECT
ON
Rotary Screw Air Compressor

Submitted by the group of 2 students

Sr. Roll Enrollment


Name of student Seat No.
No. No. No.
1 59 Pranav Onkar Warade 2100180693
2 60 Vipul Hemant Zope 2100180695

Project Guide
Prof. A. S. Chaudhari
(Lecturer in PER)
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
CERTIFICATE

This is to certify that Group Copy Roll No. 59, 60 of Fifth Semester
of Diploma in Mechanical Engineering (A) of Institute Government
Polytechnic, Jalgaon (0018) has completed the Micro Project
satisfactorily in the Subject Power Engineering And Refrigeration for
the Academic Year 2023-24 as prescribed in the curriculum.

Place: Jalgaon Enrolment No:2100180693 , 2100180695

Date: Exam Seat No:

Subject Teacher Head of the Department Principal

Seal of
Institution
GOVTERNMENT POLYTECHNIC
JALGAON

-SUBMISSION-

I P.O.W, V.H.Z Roll No./Seat NO. 59, 60 as a student of 5thSem/Year of the


Programme Mechanical Engineering humbly submit that I have completed from
time to time the Practical/Micro-Project work as described in this report by my
own skills and study between the period from / / 2023 to / / 2023 as
per instructions/guidance of Prof. A. S. Chaudhari .
And that following students were associated with me for this work,
however, quantum of my contribution has been approved by the Lecturer.
And that I have not copied the report on its any appreciable part from any
other literature in contravention of the academic ethics.

Date: ……/…../2022 Signature of Student

1)
2)
Evaluation Sheet for the Micro Project

Academic Year: 2023-24 Name of the Faculty: Prof. A .S. Chaudhari


Course: PER Course code: 22562
Semester: 5th
Title of the project: Rotary Screw Air Compressor
COs addressed by Micro Project:
A. Identify different components of IC engines and its auxiliaries.
B. Test the performance of IC engines.
C. Maintain Reciprocating air compressor.
D. Identify different components of gas turbine and jet engines.
E. Test the performance of refrigeration and air-conditioning
systems.

Comments/suggestions about team work /leadership/inter-personal


communication (if any)
…………………………………………………………………………………

Marks out of 6 Marks out of


for 4for
Roll Student Name performance in performance Total
No group activity in oral/ out of
(D5 Col.8) presentation 10
(D5 Col.9)
59 Pranav Onkar Warade
60 Vipul Hemant Zope
WEEKLY PROGRESS REPORT
SR.NO. WEEK ACTIVITY PERFORMED SIGN OF GUIDE DATE
1 Discussion and finalization
of topic

2 Preparation and
First submission of Abstract
3 Week Literature Review

4 Collection of Data

5 Collection of Data

6 Discussion and outline of


Second Content
Week
7 Formulation of Content

8 Editing and proof Reading


of
Content
9 Compilation of Report
And Presentation
10 Seminar
Third
11 Week Viva voce

12 Final submission of Micro


Project

Sign of the student Sign of the faculty


ACKNOWLEDGE

The success and final outcome of this project required a lot


of guidance and assistance from many people and we are
extremely privileged to have got this all along the completion of
our project. All that we have done is only due to such
supervision and assistance and we would not forget to thank
them.
We respect and thank Dr. Parag Patil, Principal,
Government Polytechnic, Jalgaon for providing us an
opportunity to do the project work in the institute and giving us
all support and guidance which made us complete the project
duly. We are extremely thankful to Dr. Parag Patil Sir for
providing such a nice support and guidance.
We heartily thank Mr. D. M. Patil Head Department of
Mechanical Engineering , for his guidance, suggestions and
encouragement during this project work.
We owe our deep gratitude to our project guide, Prof. K.G.
Patil , who took keen interest on our project work and guided us
all along, till the completion of our project work by providing all
the necessary information for developing a good system.
We are thankful to and fortunate enough to get constant
encouragement, support and guidance from all the Teaching
staffs of Department of Mechanical Engineering which helped
us in successfully completing our project work.
Index
Sr.no Topic Page No.

1 Introduction 8

2 Construction Of 10
screw compressor

3 Working Of Screw 12
Compressor

4 Types Of Screw 14
Compressor

5 History Of screw 15
Compressor

6 Industrial Diagram 16
of Screw
Compressor

7 Advantages of 17
Screw Compressor

8 Disadvantages 18

9 Applications 19

10 Conclusion 20
INTRODUCTION

A rotary-screw compressor is a type of gas compressor, such as


an air compressor, that uses a rotary-type positive-
displacement mechanism. These compressors are common in
industrial applications and replace more traditional piston
compressors where larger volumes of compressed gas are
needed, e.g. for large refrigeration cycles such as chillers, or for
compressed air systems to operate air-driven tools such
as jackhammers and impact wrenches. For smaller rotor sizes
the inherent leakage in the rotors becomes much more
significant, leading to this type of mechanism being less
suitable for smaller compressors than piston compressors.
The screw compressor is identical to the screw pump except
that the pockets of trapped material get progressively smaller
along the screw, thus compressing the material held within the
pockets. Thus the screw of a screw compressor is asymmetrical
along its length, while a screw pump is symmetrical all the way.
The gas compression process of a rotary screw is a continuous
sweeping motion, so there is very little pulsation or surging of
flow, as occurs with piston compressors. This also allows screw
compressors to be significantly quieter and produce much less
vibration than piston compressors, even at large sizes, and
produces some benefits in efficiency.
Figure 1

CONSTRUCTION OF SCREW COMPRESSOR


Figure.2
1. Rotors: The rotors are the main components of a screw
compressor that rotate in opposite directions to compress the
gas or air.
2. Casing: The casing is the housing that encloses the rotors
and creates a sealed chamber for compression.
3. Inlet and Outlet Ports: The inlet port allows gas or air to
enter the compressor, while the outlet port discharges the
compressed gas or air.
4. Sealing System: The sealing system prevents any gas or air
from leaking out of the compressor, ensuring high efficiency
and performance.
5. Bearings: Bearings support the rotors and allow them to
rotate smoothly.
6. Motor or Engine: The motor or engine drives the rotors to
create compression.
7. Cooling System: The cooling system helps to dissipate the
heat generated during compression and maintain optimal
operating temperature.
8. Variable Speed Drives: Variable speed drives allow for
precise control of the compressor's speed and flow rate,
improving efficiency and reducing energy consumption.
9. Oil Separator: The oil separator removes any oil that may be
present in the compressed gas or air, ensuring clean and dry
output.
10. Air Dryer: An air dryer removes moisture from the
compressed air, preventing corrosion and damage to
downstream equipment.

WORKING OF SCREW COMPRESSOR


Figure.3
Rotary-screw compressors use two very closely meshing spiral rotors to
compress the gas. In a dry-running rotary-screw compressor, timing
gears ensure that the male and female rotors maintain precise
alignment without contact which would produce rapid wear. In an oil-
flooded rotary-screw compressor, lubricating oil bridges the space
between the rotors, both providing a hydraulic seal and transferring
mechanical energy between the rotors, allowing one rotor to be
entirely driven by the other.
Gas enters at the suction side and moves through the threads as the
screws rotate. The meshing rotors force the gas through the
compressor, and the gas exits at the end of the screws. The working
area is the inter-lobe volume between the male and female rotors. It is
larger at the intake end, and decreases along the length of the rotors
until the exhaust port. This change in volume is the compression.
The intake charge is drawn in at the end of the rotors in the large
clearance between the male and female lobes. At the intake end the
male lobe is much smaller than its female counterpart, but the relative
sizes reverse proportions along the lengths of both rotors (the male
becomes larger and the female smaller) until (tangential to the
discharge port) the clearance space between each pair of lobes is much
smaller. This reduction in volume causes compression of the charge
before being presented to the output manifold.[1]
Technical Illustration of Rotary-Screw Compression system
The effectiveness of this mechanism is dependent on precisely fitting
clearances between the spiral rotors and between the rotors and the
chamber for sealing of the compression cavities. However, some
leakage is inevitable, and high rotational speeds must be used to
minimize the ratio of leakage flow rate over effective flow rate.
In contrast to Roots blowers, modern screw compressors are made
with different profiles on the two rotors: the male rotor has convex
lobes which mesh with the concave cavities of the female rotor. Usually
the male rotor has fewer lobes than the female rotor, so that it rotates
faster. Originally, screw compressors were made with symmetrical
rotor cavity profiles, but modern versions use asymmetrical rotors, with
the exact rotor designs being the subject of patents.

TYPES OF SCREW COMPRESSOR


Oil-Injected Screw Compressor: This type of screw
1.

compressor uses oil as a lubricant and coolant for the rotors,


resulting in high efficiency and performance.
2. Oil-Free Screw Compressor: An oil-free screw compressor
does not require oil for lubrication, making it ideal for
applications that require clean and dry compressed air.
3. Single-Stage Screw Compressor: A single-stage screw
compressor compresses gas or air in a single stage, making it
suitable for low to medium pressure applications.
4. Two-Stage Screw Compressor: A two-stage screw
compressor compresses gas or air in two stages, resulting in
higher pressure output and greater efficiency.
5. Variable Speed Screw Compressor: A variable speed screw
compressor allows for precise control of the compressor's
speed and flow rate, improving efficiency and reducing energy
consumption.
6. Portable Screw Compressor: A portable screw compressor is
designed for use in remote or mobile applications, providing
compressed air on the go.
7. Fixed Screw Compressor: A fixed screw compressor is a
stationary compressor that is used in industrial applications
where a constant supply of compressed air is required.

HISTORY OF SCREW COMPRESSOR


The screw compressor was first patented in 1878 by Heinrich
Krigar in Germany, however the patent expired without a working
machine being built.
The modern helical lobe screw compressor was developed
in Sweden by Alf Lysholm who was the chief engineer at Ljungstroms
Angturbin. Lysholm developed the screw compressor while looking for
a way to overcome compressor surge in gas turbines. Lysholm first
considered a roots type blower but found this was unable to generate a
high enough pressure ratio. In 1935, Ljungstroms patented a helical
lobe screw compressor which was then widely licensed to other
manufacturers. Ljungstroms Angturbin AB was renamed Svenska Rotor
Maskiner (SRM) in 1951.
In 1952, the first Holroyd cutting machine was used, by
the Scottish engineering company Howden, to produce helical lobe
compressor rotors greatly reducing both cost and manufacturing time.
In 1954, Howden and SRM jointly developed the first oil flooded screw
compressor. Flooding provided both cooling, which allowed higher
pressure ratios, and the elimination of timing gears. The first
commercially available flooded screw air compressor was introduced in
1957 by Atlas Copco.
Slot valves were developed by SRM in the 1950s, allowing for
improvements in capacity control which had been a limiting factor for
screw compressor application.
Asymmetric rotors were first patented by SRM and subsequently
introduced commercially by Sullair in 1969. The introduction of
asymmetric rotors improved sealing, further increasing the types
efficiency.

INDUSTRIAL DIAGRAM OF SCREW COMPRESSOR


ADVANTAGES OF SCREW COMPRESSOR
1.High Efficiency: Screw compressors are highly efficient and can
deliver a large volume of compressed air with minimal energy
consumption.

2. Low Noise: Screw compressors are designed to operate


quietly, making them ideal for use in noise-sensitive
environments.

3. Low Maintenance: Screw compressors require minimal


maintenance, making them a cost-effective option for industrial
applications.

4. Consistent Output: Screw compressors provide a steady


supply of compressed air, ensuring consistent performance and
productivity.

5. Compact Size: Screw compressors are often smaller and


more compact than other types of compressors, making them
easier to install and operate in tight spaces.

6. Versatility: Screw compressors can be used in a wide range


of applications, from small workshops to large industrial
facilities.

7. Durable and long lasting


8. High Demand capabilities
DISADVANTAGES OF SCREW COMPRESSOR
1. Higher initial cost: Screw compressors can be more
expensive than other types of compressors, which may
make them less accessible for smaller businesses or
individuals.
2. Limited capacity range: Screw compressors are designed
to work within a specific capacity range, which means they
may not be suitable for applications that require extremely
high or low levels of compressed air.
3. Oil carryover: Some screw compressors use oil to
lubricate the moving parts, which can result in oil
carryover into the compressed air system. This can be
problematic for certain applications, such as food
processing or medical facilities.
4. Complex design: Screw compressors have a more complex
design than other types of compressors, which can make
them more difficult to repair or maintain if something goes
wrong.
5. Heat generation: Screw compressors generate a significant
amount of heat during operation, which can be a concern
in hot environments or when cooling is limited.
6. Sensitivity to contamination: Screw compressors are
sensitive to contamination and require clean air intake to
prevent damage to the internal components.

APPLICATION OF SCREW COMPRESSOR


1. Manufacturing: Screw compressors are used in
manufacturing processes to power pneumatic tools and
machinery, such as drills, sanders, and grinders.
2. HVAC systems: Screw compressors are used in heating,
ventilation, and air conditioning (HVAC) systems to provide
compressed air for cooling and heating.
3. Food processing: Screw compressors are used in food
processing facilities to provide clean, dry compressed air for
packaging, bottling, and other food processing applications.
4. Chemical processing: Screw compressors are used in
chemical processing plants to provide compressed air for
mixing, blending, and other chemical reactions.
5. Oil and gas industry: Screw compressors are used in the oil
and gas industry to power drilling and exploration equipment,
as well as to provide compressed air for pipeline maintenance
and repair.
6. Power generation: Screw compressors are used in power
generation facilities to provide compressed air for turbine
control systems and other power plant equipment.
7. Industrial Application:- Papermaking and printing, House
appliances, Electrical and electronics, etc.

CONCLUSION
In conclusion, screw compressors are crucial machines that
provide compressed air for various industrial applications. Their
versatility, reliability, and efficiency make them an essential tool
for manufacturing processes, HVAC systems, food processing,
chemical processing, oil and gas exploration, and power
generation. With their advanced technology and high-
performance capabilities, screw compressors are a valuable
investment for any industry that requires compressed air.
The screw compressor is identical to the screw pump except
that the pockets of trapped material get progressively smaller
along the screw, thus compressing the material held within the
pockets. Thus the screw of a screw compressor is asymmetrical
along its length, while a screw pump is symmetrical all the way.

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