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International Compressor Engineering Conference School of Mechanical Engineering
1986
N. Sakurai
Fujiwara, A. and Sakurai, N., "Experimental Analysis of Screw Compressor Noise and Vibration" (1986). International Compressor
Engineering Conference. Paper 553.
http://docs.lib.purdue.edu/icec/553
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EXPERIMENTAL ANALYSIS OF SCREW COMPRESSOR
NOISE AND VIBRATION
ABSTRACT
Very few reports have been presented to date on
the noise and vibrational characteris tics of oil in-
jected screw compressors.
This time. a series of extensive experimenta l
analysis is performed. It includes the measurement s
and analysis of compressor casing vibrations. rotor
shafts vibrations, torsional <rotational) vibrations.
suction and discharge gas pulsations. pressure trans~
ient in one thread of rotors ana compressor noise.
These experiments are done mainly with R-22 gas,
and the operating speed of compressor continuously
varied up to 4400 RPM in some test conditions. The
tested compressors are mainly 1SOL<163mm ,long rotor).
Analyzed results of these experiments help to
explain the major noise and 'vibrational characteris-
tics of standard oil injected screw compressors.
Nomenclature
Fo = fundamental screw frequency, Hz
Fm male rotor operating frequency, Hz
Ff female rotor operating frequency, Hz
k specific heat ratio
n operating speed. RPM
Pd = discharge pressure. Pa
Ps suction pressure. Pa
Vi bUilt-in volume ratio
Pi built-in pressure ratio= Vik(adiabat ic change)
Zm male tooth number
Zf female tooth number
D rotor diameter. mm
L rotor length. mm
566
INTRODUCTION
Today, the oil injected screw compressors are
known as high-performanc ed and highly durable compre-
ssor and their application range has become very wide.
In spite of the amount of information concerning its
applications and performances, technical papers deal-
ing with the fundamental characteristics of noise and
vibration of the compressors seem to be very few. In
order to evaluate and reduce the noise and vibration
of the compressors. their fundamental characteristics
must be well understood. So, to aid the better under-
standing of these, we will present this summerized
report of our series of experiments concerning noise
and vibration of screw compressors.
Compression Mechanism
567
The compre ssion of a gas is ~ttained by the
a~rect volume reduct ion cf the inter- lobe space as
the rotors rotate . This is illust rated in Fig. 2.
EXPERIMENTAL TECHNIQU:E:
568
Detaile d experim ents includi ng variabl e-speed
operati on are perform ed in laborat ory test facilit ies
mainly on 1601. Also some measure ments are taken on
operati ng compre ssor in actual plant. Shown in Fig.
4 is the general arrange ment of the test facilit y.
FUNDAMENTALS
This section will Present materia ls found by
experim ents on the fundam ental charac teristic s of
screw compre ssor noise and vibrati on.
~~~~,1.~.~+.,.~~~~.~.+.,~~,..
MFILI:: TURN INC FINCI..E: t 0~!0)
Fig.S Operati on-Peri od of Pressur e & Pulsati on
569
bable causes of noise. The pressu re transi ent domina -
tes gas forces induce d on rotors and thereb y contro ls
the fundam ental noise and vibrat ion chara cteris tics.
fsr=====J
N 1601 D~163 L/D~1.65 R-22Ga s
oo;rr6 mSec
1me
Fig. 7 Operat ing Torsio nal Vibrat ion
570
forces. dynamic forces are induced on the rotors and
thereby radial and axial shaft vibrations of the
rotors occur. These vibrations are transmitted
through the bearings to the casing of compressor.The
fundamental frequencY component of rotor shaft vibra-
tions both in radial and axial directions are iden-
tical to the fundamental screw frequency. A typical
example of operating axial shaft vibration is shown
in Fig. 8.
~6-zz.---------------------------------,
c: 160L
o~l63
a"' L/0=1.65
"'
"'"
R-22
p. ~'
.--< Female
.<>til
..........
><=>
~6.22L--------------------------------8-0~mSec
0 Time
Fig. 8 Operating Axial Shaft Vibration
General Noise Characteristics
~
frequencies and ~80
are al: harmonical-
ly related.
They are ~igher
harmonics of the
fundamental screw 2
frequency \200 Hz> kHz
and the broad-band Fig.10 2kHz Range Operating
random noise Noise Frequency Spectrum
571
~nd~cates gas flow no~se. It should be noted that
the magnitudes of harmonics are approx~mately at a
constant level up to several order harmon~cs.
~.,ll~
~ T1me
~-z~iiJ----------i
""
1!1 ""'"" 1i
-.---.,!.1,......~----:,;;c;.""c;:'' ~.HJ1
'..u}........ ~~~.~~~.~
L4~~,,~
frequency
"
8 Compresso r--
"'"" -
Skid
FH!~ueney
Fig.11-c Acceleration Fig.11-d Arrangement
Fig. 11 Operating Vibration Waveform and Spectrum
572
mainly from rotor meshing. Generall y. measured vibra-
tion accelera tion values may not exceed 9.8 m/sec2 <
= 1 G>. The "Axial" directio n shows the maximum vi-
bration accelera tion level from normallY operatin g
compress ors. It should be noted that. in general.
larger vibratio n level result in higher sound level.
dB
So.regar ding the
.
Acce:lerat.ion
,.
0
selectio n of vibratio n I
measurem ent paramete r. ~ 20 I
displace ment is not ["--. I
:::
the preferre d paramete r a"-40
except in case of un- ""'
~YelocHv
Nil!
Di:spla.ceme*~
"'
balance problem because 60 .Nl I I ill .........
of its low sensitiv ity '
at high frequenc y. as Frd~uency lOO "
1000
573
~nfluence upon compressor no~se. casing vibrations
and performance. Operat~ng pressures also affect
tors~onal vibrat~on. shaft vibration and pressure
pulsations. The use of economizer also has some
effect on above mentioned vibrations.
As -!;he pressure in a rotc:r thread, .just prior to
the start of discharge phase. is only determined the-
oretically by the mult~plication between suction
pressure and built-in pressure ratio ( i.e. Ps X Pi )
without economizer. so there exists only one actual
operating discharge pressure which will exactly agree
with the theoretic~llY determined discharge pressure.
Regardless of the magnitude. there exists a certain
pressure difference between these two discharge pres-
sures. In general. the operating compressor noise and
casing vibration level ~ill increaae with the in-
crease in the pressure difference.
A measured example of compressor noise and casing
vibration shown in Table 1 indicates above mentioned
tendency under an operating discharge pressure condi-
tion. Another example under a constant operating
suction pressure condition is shown in Table 2.
Operating Speed
Operating data is used to determine not onlY the
level of noise ana vibration but also. more importan-
tly. the frequency components of these signals. By
varying the operating speed of the compressor. the
effect on frequency spectrum can be seen and the
various resonances. ~nherent in the compressor system.
can be determined.
Fig. 14 shows an example of a three-dimen tional
RPM spectrum map of generated sound pressure levels
from 160L. The peaks C at 100 Hz. 220 Hz. 275Hz and
545 Hz) are indications of various resonances.
In this case. the maximum amplitude peak at 545
Hz comes from a relative rotational resonance between
574
the male and female rotor s. and can be determ ined
the metho d of detec ting the phase differ ence betwe bY
two sinus oidal tooth passin g signa ls rom invol en
gears attach ed to each rotor s. ule
The peak at 100Hz in Fig.14 . finall Y determ ined
at 87.5 Hz in highe r freque ncy resolu tion analY
with more fine pitch chang e in the opera ting speedsis
comin g from a tors~onal resona nce in the system .is
.
And the peaks at 220 Hz and 275 Hz are confir med
to be resona nces of skid membe rs by hammer~ng metho
d.
. &27
* not in dB-sca le, E+S
in linear scale l60L
D-163
L/D~l.65
Vi-5.8
R-22
.--<:>::
~4300 rl""
<UP-<
Q.:.::
0'-'
.u <I)
<U <I)
H p.
<I) U)
p.
0
- 1500
0 Freque ncy 2kHz
PWR SP
Fig.14 3-D RPM Spectr um Map of Gener ated No~se
Pa / 4400
E+5
" .
.490 ,
"" a
..'"""'
~ 1200
"' 0 Frequen cy 2kHz
Fig. 15 3-D RPM Pulsa tion Spectr um Map
575
has occure d.
576
Type of Gas
577
/
compre ssors contai ns many compon ents from variou s
indivi dual source s. The motor. gear box. coupli ng.
piping , oil separa tor, skid and so on. They all may
combin e to yield a comple x freque ncy spectr a plot.
Here. some simpli fied exampl es are discus sed.
Piping
Fig. 20 shows an exampl e of operat ing noise from
320L test stand. The contai ned broad- band noise
spectru m result ing from gas flow noise radiat ed from
suctio n piping , can be reduce d by changi ng arrang e-
ment of the piping .
dB
lOj
~
>
,.., 320L
D32l
~
~
L/Dl,65
3000RPM
~
~
..
.,
~
~
~
0
"'
44 0 Frequenc y 5kHz
578
Gear Box <Ref. [3J)
In some appli catio ns. a multi PlYin g gear box
emplo yed to attai n large r capa city than is
that of
direc t drive opera tion. Gear set withi n
some times produ ces noise probl em becau se gear box
impro per mesh. as shown in Fig. 21. In the of its
Figu re.th e
peak at abou t 3300 Hz is corre spond ing to
.frequ ency of this gear set. And aroun d the the mesh
mesh .frequ ency. there is a serie s of equal lY prima ry
comp onent s of sideb ands. space d
These sideb ands indic ate
exist ing gear pitch error .
~ 114
l>
Cll
t-..l 200S
MFrG
~dB D"'204
r-i 1/D"= l.l
0 R-12
z
54
~ Frequ ency 5kHz
Fig. 21 Gear Noise Spect rum
DETECTION OF FAILURE
Thru st Beari ng Flaki ng
160L
D~l63
L/D~l.65
R-22 Gas
3600RPM
TIME fl LIN u~sEc
Ax:ial Ace.
579
ter of peak s
vibr ation acce lerat ion spec trum . a clus rmal ity in
at appr oxim ately 3.5 kHz indi cate s an abno
And the wave form indi cate s that the
th{~ comp resso r. impa cts
in a serie s of
unus ual sign al is gene rated .
repe ating at rela tive ly low frequ ency
abso lute
In this case . the techn ique of the oyed . and
g in the time doma in sign als is empl
aver agin ating fre~
by ~ts spect rum. show n in Fig. 23, the repe to this
quen cy is confi rmed at 322.5 Hz. Acco rding
a bear ing inne r racew ay.
frequ ency , the dama ge in ernin g the
show n {n Fig. 24. can be dete cted . Conc
ng-e leme nt
frequ enci es deriv ed by dama ge of rolli
bear ing, refe r to the Tabl e 4.
u
u
* 1 :and / o~
Wear,
occur~
* 2 :~m?litude Modula tion may
Where F1l/2 Fr(l+d /Dcos fi)
Fol/2 Fr (l-d/D cosp)
c
Fbl/2 FrD/d [1-(d/D )' cos'l'l
Fig. 24 Inne r Racew ay Fr .. Fll! or ff
Flak ing dDiam eter of Rolling Elemen t
DP;I,tc.h Diamete r
PConr.a .c.t Angle
ZcNumb er of Rolling Elemen ts
nl23 . . . .
Scuf fed Roto r Toot h [Inner Raceway Rotat~s and Outer is Station ary]
fing o
In a certa in oper ating cond ition s. scuf
roto rs some times take plac e.
200L
One typi cal exam ple of abno rmal noise rom For the
RPM is show n in Fig. 25.
oper ating at 3600 reco rded at
nois e leve l of this comp resso r.BS dBA was
of the plan t oper ation and it has in~
the begi nnin gs
of the anal y-
creas ed well abov e 100 dBA at the time s only how
sis. The over all nois e leve l indi cate
the orig in of nois e
serio us the probl em is. To dete ct zed nois e
is nece ssary . The analy
a frequ ency anal ysis fund amen tal
spect rum cont ains many sub-h armo nics of
indic ating tooth sepa ratio n and
screw frequ ency ,
580
collis ion at the point of rotor mesh contac t. The
wavefo rm also shows one collis ion takes place per
every two mesh. After inspec tion; the cause of this
abnorm ality is confirm ed result ing from scuffe d and
worn rotor tooth flanks . <The scuffe d patter n on the
rotors can be reprod uced by compu ter simula tion, an
exampl e is shown in Fig. 26.)
In this case.s cuffin g of rotors is caused by oil
compr ession at freque nt start- ups. Opera ting sequen ce
is revise d to avoid unnec essari ly long oil pump oper-
ation before compr essor starts . and the proble m was
resolv ed.
,556~
~s
200L
0~204
RERL. L/Dgl, 65
~u R-22 Gas
-. 35e
3600RPM
t
~s r t.;.s. 3m Sec
.aoSEC TIMER Se.00mHC
.Sub-har monics
X: OVII'r.!l.ll Hz r: 10t.5<B
Fig. 25 Abnorm al Noise Signal
581
.,,~
ES
2505
D-255
""' L/D-1. 1
R-22 Gas
-.6'~ 8000RPM
~+S
TIME A LIN
.
~ -.97~ Fo 2Fo
-
_3Fo. 4Fo
~dB .
ru '
"'
~
-
--
0
"" 3 7 .
0 fWR Sf A LIN lkH
SUMMARY
d
The mater ial in this repor t is direc ted towar
ding a basic under stand ing o the unda menta l
provi in-
chara cteris tics o noise and vibra tion in the oil
aecte d screw comp ressor .
With respe ct to requ ency. it can be assum ed that
the unda menta l screw requ ency <Fa Fm X Zm ; or
essor noise
=
male drive ) domin ates all aspec ts in compr
vibra tion. From the resul ts o these exper iment s
and
ession mecha nism. desig n and
it is believ ed that compr tions
manu acturi ng param eters. and opera ting condi
ure pulsa tions o disch arge and
all in1u ence on press
suctio n gas. More impo rtantl y, they in1u ence on
ni-
dynam ic gas force s induc ed on rotor s and the mechaall
ol
cal conta ct force s betwe en rotor s.ther eby contr
the chara cteris tics o noise and vibra tion.
l
In our next repor t.we will prese nt a theor etica
analy sis o screw compr essor vibra tion.
REFERENCES
[11 ASHRAE. Heric al Rotar y Comp ressor s.
1979 Equip ment Handb ook,pp . 12.14 -12.1 7.
[21 Tanak a. N .. and other s. Trans . of JSME. 1984.
vol.SO ,no.45 8. pp. 1783- 1789.
[3] Mitch el. L.D . Origi ns of Noise .Mach ine Desig n.
May 1 .1 969.
582