Screw Compressor

TRAINING RELIANCE MODULE NO.
MODULE RG-CM-R-007
TRAINING MODULE
ON
SCREW COMPRESSORS
CHECKED AND PAGE : 1 of 61

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Harmit Singh COMPRESSORS AUTHOR :Deepak Puri
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TRAINING MODULE OBJECTIVE
This Training manual is intended to help engineers to understand the basic fundamentals
and applications of screw compressors in process industry. Thus, in this module, an effort
has been made to provide, a much needed source of information in the field of screw
compressors.
To make the module easy to use, contents are divided into short sections like
• Introduction to screw compressors
• Principal of operation
• Classification of screw compressors
• Construction
• Performance characteristics
• Trouble shooting
Hope the training module serves the purpose.

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CONFIDENTIALITY STATEMENT
This Training manual is prepared exclusively for the technical knowledge enhancement
of the personnel of Reliance Group of Industries.
No part of this document may be reproduced in any form, in an electronic retrieval

system or otherwise. The document must be returned or when the recipient has no further
use of the same. The document or any part of the document is not allowed to be taken out
of the respective site or to be shared with any person outside Reliance Group.
Reliance Group of Industries reserves the right to refuse access to the above document on
the grounds of confidentiality.
Authorization for information disclosure is allowed with the written permission of the
respective Site Engineering Head.

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TABLE OF CONTENTS
SECTION DESCRIPTION PAGES
Introduction 1 to 4
1. Introduction to screw compressors
1.1 General 5
1.2 Types of screw compressors 6-10
1.3 Fundamentals of operation 11-19
2. Constructional features 20-25
3. Capacity control 26-31
4. Performance characteristics 32-34
5. Auxiliary equipment 35-42
6. Operation and maintenance guidelines 43-49
7. Condition monitoring 50-52
8. Troubleshooting 53-55
9. DOs and DONTs 56-58
10. FAQs 59-61

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INTRODUCTION TO SCREW COMPRESSORS
1.1 GENERAL
Rotary screw compressors are widely used these days in applications like air, process
gases and refrigerating gases. Industrial compressors can be categorised by their
methods of operation and type of action. Screw compressor comes into the category
of positive displacement, rotary action, medium volume and medium pressure
category. In application areas with volumes of 425 to 17000 m3/hr and pressure from
1 to 24 kg/cm2, the screw machines can be used. Other factors, which favour screw
compressors, include dirty. Fouling gases and services requiring much higher turn
down, variable molecular weight etc.
Though widely in use, it is difficult to visualise the geometry and operation of these
machines. An understanding of basics of their operation will help applying them
correctly, avoiding nuisance problems in operation and achieving the best overall
system designs.

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1.2 SCREW COMPRESSOR TYPES
As explained in introduction, there are broadly two types of screw compressors “Oil
free” or “Dry” type and “Oil injected” or “Wet” type. There have been developments
over a period of time. Different designs available now can be classified as below:
SCREW COMPRESSORS
OIL FREE OIL INJECTED
DRY LIQUID MEDIUM HIGH

INJECTED PRESSURE PRESSURE
(AIR & GAS) (GAS &
REFRIGERATION)
Operating range of dry and wet screws is shown in the below figure.

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1.2.1 DRY OIL FREE COMRPESSORS:
In this, there are only two moving components, the rotors themselves. Timing gears
are also installed on the rotors and are primarily used for synchronisation. The gears
synchronise the rotation of rotors and prevent contact of rotors between themselves
and with the casing.
This type of compressors are used for air and many process gas applications which do
not allow contamination with oil. Suitable sealing arrangement is designed for each
service. See figures below:

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1.2.2 LIQUID INJECTED COMPRESSORS:
Compression is accompanied by volume reduction and increase in temperature This

increase in temperature puts limitation on compressor design. Temperature increase
in certain gas mixtures poses problems like ‘polymerisation’, ‘gumming’ etc. Hence
suitable liquids like water, benzol, other solvents etc are injected in the process gas
which control the temperature rise by absorbing heat of compression.
1.2.3 OIL INJECTED SCREW COMPRESSORS:
The fundamental difference between the oil free and oil injected screw compressors is
that in oil injected, lubricant is added to the gas being compressed and removed again
after the compression is complete.
It can be stated that the power absorbed in compressing a gas all appears as heat in
the system. Normally the vast majority of this heat appears in the gas itself as increase
in temperature, the remainder being absorbed in the compressor and its cooling
systems. However, in an oil injected compressor, a large part of the mass flow going
through the compressor is made up of the injected oil and hence this absorbs the heat.
The mass of oil is relatively large compared to the gas mass flow because the oil is in
the liquid phase, but the volume of the oil relative to the gas is normally less than 1%
and therefore, the effect of oil volume on the gas throughput of the compressor is
negligible.
The addition of the appropriate quantity of oil to the compressor related to the
absorbed power therefore, controls the compressor discharge temperature regardless
of the pressure ratio over which it is operating. As long as the cooling for the oil is
designed to remove the heat absorbed by it, the system remains under accurate control
with great flexibility. A typical oil injected screw compressor is shown on the next
page.

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1.3 FUNDAMENTALS OF OPERATION
A screw compressor is best described as a positive displacement volume reduction

device. Its action is analogous to a reciprocating compressor more than any of the
other common compressor types. It is helpful to refer to the equivalent recip. Process
to visualise how compression progresses in a screw. Gas is compressed by pure
rotary motion of the two intermeshing helical rotors. Gas travels around the outside of
the rotors, starting at the top and travelling to the bottom while it is transferred axially
from the suction end to the discharge end of the rotor area.
SUCTION PROCESS :
Suction gas is drawn into the compressor to fill the void where the major rotor rotates
out of the female flute on the suction end of the compressor. Suction charge fills the
entire volume of each screw thread as the unmeshing thread proceeds down the length
of the rotor. This is analogous to the suction stroke in a reciprocating compressor as
the piston is drawn down the cylinder. See figure 1.
FIGURE 1
The suction charge becomes trapped in two helically shaped cylinders formed by the
screw threads and the housing as the threads rotate out of the suction port. The
volume trapped in both screw threads over their entire length is defined as the volume
at suction (Vs). In the recip analogy, the piston reaches the bottom of the stroke and
the suction valve closes, trapping the suction volume (Vs). See figure 2

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FIGURE 2
The displacement per revolution of the recip. Is defined in terms of suction volume,
by the bore times the stroke times the number of cylinders. The total displacement of
the screw compressor is the volume at suction per thread times the number of lobes
on the driving rotor.
COMPRESSION
The male rotor lobe will begin to enter the trapped female flute on the bottom of the
compressor at the suction end, forming the back edge of the trapped gas pocket. The
two separate gas cylinders in each rotor are joined to form a “V” shaped wedge of gas
with the point of the “V” at the intersection of the threads on the suction end. (See
figure 3). Further rotation begins to reduce the trapped volume in the “V” and
compress the trapped gas. The intersection point of the male lobe in the female flute
is like the piston in the recip. That is starting up the cylinder and ompressing the gas
ahead of it. See figure 4.

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FIGURE 3
FIGURE 4

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DISCHARGE PROCESS
In the recip. Compressor, the discharge process starts when the discharge valve first
opens. As the pressure in the cylinder exceeds the pressure above the valve, the valve
lifts, allowing the compressed gas to be pushed into the discharge manifold. The
screw compressor has no valves to determine when compression is over. The location
of the discharge ports determine when compression is over. See figure 5. The volume
of the gas remaining in the “V” shaped pocket at discharge port opening is defined as
the volume at discharge, Vd.
FIGURE 5
A radial discharge port is used on the outlet end of the slide valve and an axial port is
used on the discharge end wall. These two ports provide relief of the internal
compressed gas and allow it to be pushed into the discharge housing. Positioning of
the discharge ports is very important as this controls the amount of the internal
compression.
In the recip., the discharge process is complete when the piston reaches the top of the
compression stroke and the discharge valve closes. The end of the discharge process
in the screw occurs as the trapped pocket is filled by the male lobe at the outlet end
wall of the compressor. See figure 6. The recip. Always has a small amount of gas
(clearance volume), that is left at the top of the stroke to expand on the next suction
stroke, taking up space that could have been used to draw in more suction charge. At
the end of the discharge process in the screw, no clearance volume remains. All
compressed gas is pushed out the discharge ports. This is a significant factor that
helps screw compressor to be able to run at much higher compression ratios than a
recip.

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FIGURE 6
Above compression cycle has been illustrated in the following drawing as a whole:

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VOLUME RATIO:
In a reciprocating compressor, the discharge valves open when the pressure in the
cylinder exceeds the pressure in the discharge manifold. Because a screw compressor
does not have valves, the location of the discharge ports determine the maximum
discharge pressure level that will be achieved in the screw threads before the
compressed gas is pushed into the discharge pipe.
Volume ratio is a fundamental design characteristic of all screw compressors. The

compressor is a volume reduction device. The comparison of the volume of the
trapped gas at suction Vs, to the volume of the trapped gas remaining in the
compression chamber when it opens to discharge Vd, defines the internal volume
reduction ratio of the compressor. This volume index or Vi determines the internal
pressure ratio of the compressor and the relationship between them can be
approximated as follows:
Vi = Vs / Vd
where, Vi: Volume ratio or index

Vs: Volume at suction
Vd: Volume at discharge
Pi = Vi k
where, Pi: Internal pressure ratio

k: specific heat ratio of the as being compressed.
Only the suction pressure and the internal volume ratio determine the internal
pressure level in the trapped pocket before opening to the discharge port. However, in
all refrigeration systems, the condensing temperature determines the discharge
pressure in the system, and the evapourating temperature determines the suction
pressure.
If the internal volume ratio of the compressor is too high for a given set of operating
conditions, the discharge gas will be kept trapped too long and be raised above the
discharge pressure in the piping. This is called as overcompression and is represented
in the pressure-volume curve in Figure 7. In this case, the gas is compressed above
discharge pressure and when the port opening occurs, the higher pressure gas in the
screw thread expands out of the compressor into the discharge line. This takes more
energy than if the compression had been stopped sooner, when the internal pressure
was equal to the system discharge pressure.

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FIGURE 7
When the compressor volume ratio is too low for the system operating pressure, this
is called as undercompression and is represented in Figure 8. In this case, the
discharge port opening occurs before the internal pressure in the compressor trapped
pocket has reached the system discharge pressure level. The higher pressure gas
outside the compressor flows back into the lower pressure pocket, raising the thread
pressure immediately to the discharge pressure level. The compressor then has to
pump against this higher pressure level, rather than pump against a gradual build up
to discharge pressure level if the volume ratio had been higher, keeping the trapped
pocket closed longer.

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FIGURE 8
In both cases the compressor will still function, and the same volume of gas will be
moved, but more power will be required than if the discharge ports are correctly
located to match the compressor volume ratio to what the system needs. Variable
volume ratio compressor designs are used in order to optimise discharge port location
and minimise compressor power.

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CONSTRUCTIONAL FEATURES
A typical twin screw compressor consists of a pair of a male rotor and a female rotor
mounted on bearings to fix their position in a rotor housing which holds the rotor in
closely toleranced inter-sectioning cylindrical bores. The rotors basic shape is a screw
thread with varying number of lobes or male and female rotors. The constructional
features differ for wet screw compressors and dry screw compressors. The main
differences include:
1. Dry screw compressors have timing gears installed on both rotors while the wet screw
compressors don’t have these.
2. Bearings are lubricated by a dedicated lube oil system in case of dry screw while in
case of wet screws, the bearings are lubricated by the same oil which is also used for
injection into the machine.
3. Dry twin screw compressors require elaborate sealing systems and two separate seals
while wet screw requires only one seal and has a fairly simple seal system.
The drive is given to the male rotor which in turn drives the female rotor. The
bearings could be antifriction bearings or sleeve bearings depending upon the
machine size and thrust bearings are installed on one end to take care of the axial
thrust. A typical screw compressor is shown in the next page in an exploded view.

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2.1 SCREW COMRPESSOR ROTORS:
As shown in the figure, the rotors with their bearings and sealing journals are single
piece forgings from high quality carbon steel or Cr Ni alloy steel.
An asymmetric rotor profile guarantees high efficiencies. Narrow sealing strips are
machines on the tips of the male and female rotors to ensure proper sealing between
the rotors themselves and the casing walls. The rotors are constructed with
asymmetric rotor profile with 4 (male) and 6 (female) rotor lobes. This is a widely
accepted combination which offers good efficiency. Other combinations like 3 (M)
and 5(F) lobes are used for some applications.
Each rotor is individually dynamically balanced. In case of dry screws, rotors are
balanced alongwith the timing gears.

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2.2 CASINGS:
Different vendors use different design of casings. Casings in horizontal split design as
well as in vertical split designs are manufactured. The materials used are generally
cast iron and cast steel. Many a times special materials like high Nickel low
temperature steel or titanium is used for some applications. Some casings are built
with cooling jackets to minimise the temperature effects and hence permitting high
operating conditions while still maintaining high efficiency.
2.3 BEARINGS:
Rotors are supported in white metal sleeve bearings. These are of steel bush type lines
with white metal and lubricated by a pressurised lube system.
As one end of the rotor is subjected to discharge pressure while the other end is
subjected to suction pressure, an axial thrust is developed on both the rotors. This is
supported by tilting pad thrust bearing or taper land bearing. These bearing not only
take care of the thrust but also positions the rotor in the casing with suitable
clearances as specified.
Antifriction bearings are also used as radial and thrust bearings depending upon the
bearing loads in smaller frame sizes.
2.4 TIMING GEARS:
In case of oil free (dry screws) compressors, high quality precision ground helical
timing gears are fitted which ensure that rotor lobes never come in contact during
operation. Owing to the geometry profiles and their meshing characteristics, the male
rotor absorbs 85% of the compressor power and the female only 15%. As the drive is
applied to the main motor only, the timing gears are primarily for synchronisation and
not for load transmission.
2.5 SEALS:
Variety of seals are used for these machines. Carbon bushings, mechanical contact
seals and floating bush seals are the most widely used seals.
While sealing of the air or inert gases is fairly simple, sealing of the process gases and
refrigerants call for more elaborate arrangements. In such services where process gas
can not be vented to atmosphere, liquid seal system can be effectively used in which

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mechanical contact seals are used. A typical mechanical contact type seal has been
shown below:
Mechanical contact seal alone or in combination with carbon ring seals gives positive
sealing under all conditions, including standstill. As the amount of leakage oil from
the contact seal is only small, the oil in contact with the gas can be discarded. A
combined lube / seal oil system can be employed.
2.6 COUPLINGS:
Dry couplings like metal disk pack couplings or profile diaphragm couplings are used
for these machines.

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CAPACITY CONTROL
Capacity control is used in screw compressors to vary the amount of gas drawn into
the compressor. This is necessary in order to provide accurate suction temperature
control as evapourator load varies. Common capacity control methods are:
♦ Slide valve controlling discharge port
♦ Slide valve controlling discharge port and volume ratio
♦ Slide valve not controlling discharge port
♦ Plug valves
♦ Variable speed
Slide valves controlling the discharge port are a very common type of capacity
control device used in screw compressors. They are popular because they can give
infinitely adjustable control of capacity, often from 10 to 100%. This type of slide
valve works by opening a recirculation passage in the high-pressure cusp which
allows a portion of the trapped gas in the “V” shaped compression chamber to be
recirculated back to the suction cavity before it begins compression. See figure. This
method offers good efficiency at part load for two reasons. First, the recirculated gas
only has to overcome a slight pressure drop in order to bypass back to suction since
the recirculation slot opens to the trapped pocket before compression has started,
avoiding a precompression loss. Second, as the slide valve moves, the radial
discharge port is also being moved. As the trapped volume at suction is decreased, the
discharge port opening is also delayed, thus maintaining approximately same volume
ratio at part load as at full load for optimum part load efficiency.

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A compressor designed to control capacity and volume ratio is shown in the figure. In
this design the discharge port position and the recirculation slot position can both be
adjusted. This allows an infinite number of adjustable positions for both valves,
which provides volume ratio and capacity adjustment from full load to approximately
40% load, with continuing capacity adjustment down to 10% load. This arrangement
offers improved energy efficiency at full and part load.
Slide valves that do not control the discharge port come in several varieties, the most
common is a round slide valve intersecting with slots in the rotor bore. See figure.
This type of unloader still gives good reduction of capacity but not as good a
reduction in part load power because it does not maintain the volume ratio during
unloading. There can also be some leakage accross the slots in the rotor bore which
can hurt performance at all loads. These devices are lower in cost than conventional
slide valves and used in some smaller compressors.

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Plug valves are radial or axial devices which lift to open a recirculation passage from
the trapped pocket back to suction. They will typically give unloading in steps of 75,
50 and 25% at full load as each progressive plug is opened. These devices also do not
give part load volume ratio correction like the first slide valves, thus part load
efficiency is comparable to slide valves that do not regulate the discharge port. Plug
valves also tend to be lower cost and simple in control method. See figure.
Variable speed:
Variable speed is occasionally used as a method of capacity control with screws. This
can be provided with speed controlled engines, steam turbines, or variable frequency
electric drives. Compressor power does not decrease linearly with speed reduction but
rather decreases as a function of rotor tip speed, and operating compression ratio. In
general, the compressor part load efficiency will be slightly better at low compression
ratio and significantly better at high compression ratio with reduced speed compared
to slide valve control, but this is before taking into account the losses in the driver at
reduced speed.
Typical variable frequency drives will cause a loss in efficiency of around 3% at full
load. They will also cause an additional loss of motor efficiency of 2.5%. This gives a
full load efficiency loss of about 5.5%. With some drives this loss may stay at the
same relative horsepower level as the drive speed is reduced, effectively becoming a
larger percentage loss at lower speeds. If a compressor will operate at part load, and
at high compression ratio for many hours per year, the cost of the drive may be
justified. If a compressor operates near full load for a high percentage of time, or
operates primarily at low compression ratios, it is unlikely that there is any advantage
with a variable speed drive, or that the cost of the drive can be justified against slide
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valve control. See typical curves below for differences in power consumption. These
curves are calculated assuming drive and motor losses are a fixed percentage of
power not fixed kW at reduced speed.
Whether variable speed is justified as a part load method must consider the load
profile and operating conditions that are expected in a particular application.

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Variable speed control with screws should not be implemented without consulting
compressor manufacturer. There are lower speed limits for compressors below which
bearings may fail due to inadequate bearing lubrication. Large compressors will have
lower minimum speeds than small compressors. Many small compressors may be
able to accommodate drive speeds above the input line frequency, but separator
limits, oil cooler size, and other package limitations must be investigated. It is also
possible to fill a compressor up with oil and cause failure if the speed is reduced
below an acceptable range with the compressor unloaded. Many of these limits are
not published but should be investigated early in a variable speed proposal or study.

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PERFORMANCE CHARACTERISTICS
As has been explained earlier, screw compressors are positive displacement machines.
Their utility lies in the fact that these machines can handle dirty gases, gas mixtures
having tendencies to polymerise at high temperatures, gases containing liquid entrapment
etc. Additionally it can accommodate changes in molecular weights and pressures.
The typical characteristic curve for a screw compressor is shown in the figure on next
page. As can be seen, the characteristic of the machine is almost a vertical line with some
slant. With differential head on Y-axis and capacity on X-axis. This means for a
particular speed and fixed volume ratio, the discharge pressure varies appreciably even
for small changes in inlet volume. The figure also shows as to how the specified
discharge pressure is obtained at much reduced inlet volumes by change of speed.

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AUXILIARY EQUIPMENT
Large screw machines, as in case of centrifugal or reciprocating machine, do require

dedicated auxiliary system, which facilitate the machine to run with maximum
availability and reliability. The system requirements include:
♦ LUBE OIL SYSTEM

♦ SEAL OIL SYSTEM
♦ SILENCERS
♦ KNOCK- DOWN DRUMS
♦ ENCLOSURES
5.1 LUBE OIL SYSTEM
A pressure lubrication system is employed incorporating an oil cooler having sufficient

capacity to dissipate the heat absorbed from bearings and during the compression (in case
of wet screws).
The system consists of a main lube oil pump with stand by with auto changeover. Proper
functioning of lube oil system is must, hence the lube oil system should be properly
designed. Provision of accumulation should be considered to improve its reliability.
5.2 SEAL OIL SYSTEM
Most of the compressors are equipped with mechanical contact seals to prevent the
leakage of process gas to the atmosphere. When equipped with contact seal, seal oil
system is generally combined with the lube oil system. The system is such designed that
the function / health of seals can be known from the operating parameter like pressure
and flow of supply and drain lines. The system is designed with suitable protection on
excessive leakage. When machines are used in sour services, buffer gas can also be used,
which prevents process gas to come in contact with oil. A typical mechanical contact type
seal is shown below:

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5.3 OIL SYSTEMS: SEPARATION AND COOLING
As pointed out, oil injection performs many useful functions in the screw compressor,
however, since oil is not desirable in other parts of the refrigerating system, oil flooded
screws bring with them the need for oil separators. One type of oil separator design is
seen in attached figure. The mixture of discharge gas and oil leaving the compressor is
directed against one head of the oil separator where it experiences a change in direction
and a large reduction in velocity. The larger oil particles are drawn to the oil sump by
gravity, with the smallest particles, or oil smoke being carried in to the coalescing filters.
Here, these small particles impact on the internal fibres in the filters and coalescing into
larger oil droplets which can then be collected in the dry end sump and returned to a low
pressure area in the compressor. Besides removing oil from the gas stream, the separator
also gives the oil in the main sump time for any liquid refrigerant droplets to absorb heat
and vaporize , or entrained bubbles to rise to the surface of the oil, giving a more pure oil,
giving a more pure oil for reinjection in the compressor.
Since most of the heat of compression is transferred to the oil during compression, this
heat must be removed by an oil cooling system. The three most common system are
water cooled, thermosyphon cooled, or liquid injection. While air cooled coolers are
possible they are not as popular as the above three system and will not be addressed here.

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WATER COOLED OIL COOLING:
Referring to below figure, the hot oil leaves the oil separator, through a strainer into the
oil pump. The oil is pumped through a shell and tube or plate type heat exchanger where
the heat is rejected to circulating water, or glycol. The cool oil is then filtered and
returned to the compressor for reinjection. Primary disadvantages of this system involve
the initial cost and maintenance of the water or glycol system, and risks of tube rupture,
or plugging if proper water condition is not maintained. It is generally preferred to leave
water flow to the cooler at a fixed rate and use a temperature regulated mixing valve on
the oil side of the cooler to blend hot and cold oil to the desired reinjection temperature.
This will help to minimize water side fouling of the tubes by maintaining a higher
minimum water velocity. The use of closed loop glycol eliminates fouling risks.

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THERMOSYPHON OIL COOLING
Today, thermosyphon is the most common type of oil cooling in industrial plants. A
typical thermosyphon system is shown in following 2 figures. The thermosyphon system
is similar to the water-cooled system except the water is replaced by refrigerant boiling
on the tube side of the oil heat exchanger. The thermosyphon system is basically a
flooded evaporator, fed by the gravity head of a tank of liquid refrigerant in a
thermosyphon receiver, elevated above the level of the heat exchanger. As hot oil enters
the shell side of the heat exchanger, refrigerant boils in the tube side with the bubbles
rising in a return line back to the thermosyphon receive. Vapor generated by this process
is vented back to the condenser inlet where it gives up heat and returns with the system
liquid. In effect the thermosyphon oil cooler is a gravity flooded evaporator, with its
evaporating temperature at the condenser.
Thermosyphon system are popular because they require virtually no maintenance and
they do not degrade compressor performance. Modest cost is required for installation, and
piping can occasionally be challenging, particularly in system with little headroom, or old
engine rooms where the piping contractors has to get creative.

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LIQUID INJECTION OIL COOLING
Liquid injection cools the oil direct injection of refrigerant liquid into a low pressure
screw thread, part way down the compression process as seen in below figure. The oil
and the discharge gas are controlled to the desired temperature by a thermal expansion
valve. This valve controls the injected liquid flow to maintain the temperature of a
thermal bulb installed in the compressor discharge line.
Some of the injected liquid expands through the expansion valve into the screw threads,
requiring additional power to compress it. All of the remaining liquid mixes with the oil
and is carried down the discharge line with the discharge gas. The injected liquid remains
in the compressor less than 0.01 second. As heat transfer takes time, much of the cooling
takes place in the discharge line and the oil separator, where the liquid has time to absorb
heat and be evaporated. Some of the liquid mixed with the oil will leak through internal
compressor clearance to the suction. Oil leaked to suction has little effect, however, the
liquid will expand into the suction as vapor, with a large increase in specific volume,
reducing the amount of suction charge that can be drawn in. This causes a reduction in
capacity with liquid injection, with larger effect at high compression ratios.

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Low initial cost, and low maintenance made liquid injection popular several years ago,
however, the power and capacity penalties make it unattractive for most applications with
high heat of compression. Liquid injection is also not recommended for systems with
even temporary conditions of high suction, and low head, where inadequate differential
across the expansions valve causes erratic liquid feed.
5.4 SILENCERS
Screw compressors are positive displacement machines, the flow pattern is pulsating and
is generally associated with high frequency vibration and noise. Properly designed
silencers shall ensure vibration and noise free flow.
5.5 KNOCK OUT DRUMS
Though small amounts of liquid entrapment can be tolerated by the machines, knock out
drums are provided in the suction line which remove the liquid and condensable, hence
improve equipment reliability.

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OPERATION AND MAINTENANCE GUIDELINES
Operation and maintenance procedures would generally be specific to each machine as it

would depend upon many factors as described below:
♦ Type of construction
♦ Service
♦ Lube / seal oil system
♦ Driver
♦ Capacity control system
♦ Cooling system
Hence specific procedures, SOPs and SMPs must be prepared and practiced. For
reference typical operation and maintenance guidelines are given for an oil-free twin
screw process gas compressor.
OPERATION:
A] PRE-START PROCEDURE
Before starting the unit for the first time, and always after a major overhaul or repair,
check the following:
1. Be sure the intake, all oil and air piping and internal parts of the unit are free from dirt
and moisture.
2. Remove paint and preservative coating, if used, from all moving parts. (See
instructions for removing preservatives)
3. Extreme care must be taken to prevent foreign material such as nuts, bolts, tools etc
from remaining in or dropping into any of the piping or compressors.
4. See that all bolts and nuts are secure. Some may have loosened in shipment.
5. Check alignment
6. Lubrication- in preparation for start up, flush the lube oil system and adjust the lube
oil pressure switches. Check all switch settings in accordance with the lube / seal oil
console section.
7. See that all valve internal to the unit are properly adjusted.
8. Check all other auxiliary equipment including safety alarm system to see that it is in
proper order
9. Check compressor side inlet drain for condensation at initial start and after a
shutdown period.

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B] INITIAL STARTING PROCEDURE
1. Run driver up to speed without load as follows:

♦
isconnect coupling between driver and gear
♦
ump driver and check rotation
♦
un driver up to speed, checking for undue noise and vibration
2. Run driver and gear.

♦
isconnect coupling between gear and compressor
♦
heck alignment between driver and gear
♦
onnect coupling between driver and gear
♦
tart lube oil pump and check pressures and flows to gear
♦
ump driver and check gear rotation
♦
un driver and gear up to speed, checking for undue noise and vibration
3. Run in compressor on gas as follows:

♦ Install temporary wire screens at the joint between the compressor and inlet silencer
to catch any weld berries, slag or dirt remaining in the pipe. Screen information is
found at the back of this section. Remove screen before putting unit into service.
♦ Bar compressor over by hand to check for freeness. If any metal- rubbing-on metal
sounds are detected in the compressor, determine the cause and correct the same
before starting. Use strap wrench to bar compressor.
♦ Check alignment between the gear and the compressor. Couple compressor to gear.
♦ Turn on buffering gas and/or other sealing fluid to compressor.
♦ Start main oil pump and check flows and pressures to bearings. Oil temperature
should be 16 oC to 27 oC before starting unit.
♦ Make sure process shutoff valve and bypass valve are open.
♦ Run driver for a period just long enough to bring the unit up to approx. ¼ speed, trip
off driver and observe the unit while it coasts to a stop to make sure there is no undue
vibration or noise. Bar unit over again to check for freeness.
♦ Start driver and bring unit up to speed. Do not operate for more than two minutes
with zero discharge pressure.
♦ Gradually close down on the bypass valve and bring unit up to 50% of discharge
temperature over a period of 15 minutes. (if applicable)
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♦ Run for 30 minutes at above condition and observe operation of unit and auxiliary
equipment. Check for any unusual vibration or noise.
♦ Stop driver and let unit coast to a stop.
♦ Bar unit over to check for freeness.
♦ Check inlet screen and clean if necessary
♦ Continue to operate unit for 30 minute interval until inlet screen is no longer picking
up dirt
♦ Always turn injection water off immediately before shutting off main driver. (if
applicable)
C] NORMAL STARTING PROCEDURE
After all the precautionary measures have been taken, the unit can be started as follows:
1. Turn on the seal buffering gas (if applicable)

2. Start the main lube oil pump for prefabrication. Prelube compressor approx. One hour
at initial start and for 10 minutes after each shutdown and at each subsequent start.
Start pressure gauges and sight glasses for oil flow.
3. Turn on the cooling water so that a steady continuous supply flows into the unit
4. Check all valves external to the machine for proper adjustment
5. Bar unit over using strap wrench.
6. Make sure process shut off valve and bypass valve is open. Start the driver in
accordance with the manufacturer’s instructions and bring unit up to speed. Gradually
choke down on bypass valve and bring unit up to pressure over a period of approx. 15
min.
7. Check all lube oil pressure gauges and sight flow indicators to see that the machine is
being properly lubricated. Also observe temp. Gauges.
8. Observe the action of the machine to make sure there is no undue vibration or noise.
9. Check auxiliary equipment. Be sure the unit is not operating beyond the rating
stamped on the nameplate
10. In the event of an emergency shutdown while unit is operating, do not attempt to
restart compressor until it bars over freely.
D] NORMAL OPERATION
Some conditions are subject to slight variations as listed below:
1. Process gas pressures and temperatures - changes in process requirements may cause
a variation in operating temperatures and pressures. System temperatures will vary
directly with incoming gas temperatures. Temperature differential between inlet and
discharge nozzles should remain fairly constant. Pressures will be dependent upon
and affected by incoming gas and barometric conditions.

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2. Bearing temperatures - bearing temperatures will vary slightly with ambient

temperature and with lube oil temperature. Higher lube oil temperatures will produce
proportionately higher bearing temperatures. A variation of 6 oC to 11 oC in bearing
temperatures is of no consequence.
A running plot of all temperatures and pressures is advisable. Log all gauge pressure
and temperature readings at initial start after unit has reached normal operating
conditions. Use these initial readings as a guide and check frequently as
recommended in “operational inspection”
Any rapid or gradual change, not due to process conditions, may indicate a possible
malfunction.
E] SHUTDOWN PROCEDURE
When unit is to be taken off the stream and shutdown, the following procedure should
be followed:
1. Gradually open bypass to reduce discharge pressure to ½ normal pressure. Operate

unit at this condition for approx. 20 minutes or until the gas discharge temperature
levels off.
2. Stop unit. If unit starts turning backwards, immediately close the block valve.
3. Allow lube oil to circulate for 10 minutes after the unit is stopped to properly cool the
rotors.
4. If unit is to be shutdown for an extended period in a freezing environment, drain all
water from oil coolers, compressor jackets and piping.
5. If unit is shutdown for an extended period of time, following maintenance program
should be followed to keep unit ready for service:
♦ Open compressor inlet casing drains to allow condensate to drain out

♦ Circulate lube oil for a minimum of one hour once a week and rotate unit several
revolutions.
♦ For extended down periods, remove silencers and piping from compressor inlet
and discharge and spray a light film of lubricating oil on rotor surfaces and
machines internal housing surfaces once every two weeks to prevent rusting
If the unit shuts down instantly under full load (power failure, emergency shutdown),
following procedure is to be followed if unit is to be started:
1. Let the cooling water flow through the oil cooler and compressor
2. Circulate the lube oil for one hour and rotate the compressor drive shaft ¾ turn by
hand every 10 minutes
3. Turn until over by hand three revolutions. The unit is ready to restart when it turns
normal with no tight areas.
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4. Restart unit in normal manner. Operate at approx. ½ normal pressure for 15 min
before applying rated pressure
MAINTENANCE AND INSPECTION
The installation should be inspected regularly at intervals that will be determined by the
severity of operating conditions. For convenience, suggested maintenance routine may be
segregated into two separate but interdependent classifications as follows:
I] OPERATION INSPECTIONS
An accurate operational inspection system is the best means of detecting the need for
maintenance work.
a) Continuous log or graph of all pressure and temperature readings should be kept.
For the first few weeks of operational break-in, 4 readings per 8 hour shift are
recommended. After that, the readings could be reduced to a suggested minimum
of two per shift. Any rapid changes in consecutive readings would indicate
possible malfunction and should be investigated immediately. Any gradual but
consistent change not related to normal ambient or process variations should also
be investigated.
b) Any change in the characteristic should or increase in vibration of the unit should
be investigated.
c) Oil and water leaks should be repaired when first observed.
d) The water flow from jacket, after cooler and oil cooler should be observed when
each reading is taken.
e) Check lube oil level in reservoir.
f) Make all checks recommended for the main driver.
II] PERIODIC INSPECTION
a) Every 500 – 700 hours: Check operation of alarms and controls.

b) Every 1000 – 1500 hours: Drain oil sample from reservoir. Check oil for
oxidation, contamination and water. Frequency of oil change depends upon this
analysis.
c) Every 7500 – 8500 hours (Annual):
♦ Inspect rotors through inlet and discharge nozzles. Some polish areas on the
rotor lobes are to be expected, due to float and relative shift of the rotors
during start up and shutdown. Excessive rubbing between rotors or wear on
radial and end sealing strips will require readjustment or possible replacement
of the bearings.

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♦ Remove discharge end cover and inspect timing gears. There should be even
wear pattern on gear teeth.
Measure thrust bearing end clearance with a dial indicator. Measure dial
bearing clearance with a dial indicator mounted through thrust bearing
housing drain opening.
♦ Loosen inlet end cover and visually inspect radial bearings.
♦ Remove compressor jacket cover plates and inspect for sediment or calcium
deposits. Clean if necessary.
♦ Remove coupling guards and inspect couplings for broken shims.
♦ Recheck alignment at all couplings.
♦ Check and reset, if necessary, all temperature and pressure gauges and
pickups.
♦ Inspect inside of silencers for deterioration of foreign materials.
♦ Inspect water side of after cooler and oil cooler for foreign material or calcium
deposits and clean if necessary.
d) Every 15000 hours (2 years):
♦ Inspect per paragraph 2c.

♦ Remove coupling hub at inlet end cover. Measure inlet radial bearing
clearances with a dial indicator mounted adjacent to the bearing.
e) Every 30000 hours (4 years):
♦ Inspect per paragraph 2d.

♦ Remove and inspect timing gears, thrust bearings, radial bearings and seals.
♦ With radial bearings in place, indicate shaft runout at all diameters of each
shaft with a dial indicator.
♦ If condition dictate, remove the rotors from the housing, clean and inspect the
rotors and housing bores.

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CONDITION MONITORING
Condition monitoring involves the fitting of instrumentation to machinery, which

provides information on the running of various parts of the equipment and indicates
change in any parameter.
The purpose of this information is to foresee the need for overhaul or adjustment before
failure occurs. The normal parameters involved are temperature and vibration.
Temperature:
It is normal to fit instruments which record oil supply temperatures, compressor

discharge temperatures and where relevant, compressor suction temperatures and
therefore, these are not considered as condition monitors other than they may such things
as fouling of heat exchangers etc. Bearing temperature detection can provided a more
significant indication of condition. In a screw compressor fitted with solid white metal
journal bearings and tilting pad thrust bearings, temperature detectors can be placed
against the steel backing of the white metal, as close to the white metal (babbit metal)
running surface as possible and in the same way in one of the tilting pads. Alternatively
the temperatures detectors can be located to measure the oil drain temperatures at
signification positions.
The results obtained have to be interpreted with care. A significant change in the running
temperature could be caused by an equivalent rise in the oil supply temperature or a
variation in the compressor duty and due allowance must always be made for such
factors.
A gradual change in one more bearing temperature readings can warning of impending
problems, permitting a planned shut down to be organized.
Vibration:
These devices are available in two basic forms. The first is an accelerometer mounted
directly on to the machine external casing and the second is a series of probes located
close to rotating shafts to detect changes in lateral and axial movement.
Fitting the casing mounted unit is an economic system, which is used quit extensively. It
is set such that a significant increase in compressor vibration sets off an alarm or
shutdown trip. An increase in vibration can be caused by problems within the machine
but also can be caused externally such as by coupling failure or misalignment. It is
sometimes necessary to fit a time delay during the starting sequence as initial vibration
can occur which subsides when normal running speed is reached.

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Axial probes are provided at the end of the both rotors on large machines. These probes
give good indication about the rotor position, gradual wear of bearings and thus overall
machine condition.
VIBRATION CLASSIFICATION
20
10
DOUBLE AMPLITUDE: INCHES X 10-3
0.5
0.2
0.6 1 2 5 10 20
3
FREQUENCY: CYCLES/MIN X 10
FIG: METHOD OF ASSESSING PEAK TO PEAK

VIBRATION MEASUREMENTS

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TROUBLESHOOTING
No Trouble indication Cause Correction

1 Insufficient Capacity 1 Restricted suction line Clean suction line
2 Speed incorrect Check main driver
3 Dirty inlet filter Clean filter
4 Excessive clearances Replace worn parts and adjust
rotor to rotor and rotor to
housing clearances
5 Relief valve opening Adjust relief valve setting
6 Excessive system leakage Repair all leaks
7 Suction throttle valve out of Readjust throttle valve control
adjustment
2 Insufficient Pressure 1 Excessive system leakage Repair all leaks
2 Speed incorrect Check main driver
3 Relief valve opening Adjust relief valve setting
4 System demand exceeds
compressor capacity
5 Faulty pressure gauge Reset or replace gauge
3 Excessive pressure 1 Relief valve incorrectly set Reset relief valves
2 Compressor capacity greater
than system demand
3 Faulty pressure gauge
4 Inetrcooler pressure 1 Compressor discharge
excessive pressure too high
2 Insufficient cooling Clean intercooler and cooling
water system
3 Excessive clearances in Replace worn parts and adjust
compressor unit rotor to rotor and rotor to
housing clearances
5 Intercooler pressure 1 Compressor discharge
below normal pressure too low
2 Excessive cooling Adjust intercooler water supply

Dirty inlet filter Clean filter
6 Discharge gas temp. 1 Excessive clearances Replace worn parts and adjust
High rotor to rotor and rotor to
housing clearances
2 Excessive discharge pressure See trouble indication 3
3 Insufficient intercooling Clean coolers and cooling
water system
4 Insufficient jacket cooling Clean and flush jackets and
adjust water systems
5 Abnormal intercooler pressure See trouble indication 4, 5

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6 Discharge gas temp. 6 Compressor malfunction Check rotors for evidence of

High rubbing. Reset clearances, if
necessary
7 Faulty suction throttle valve Readjust throttle valve control
8 Dirty inlet filter Clean filter
7 Cooling water 1 Excessive clearances Replace worn parts and adjust
discharge temp. High rotor to rotor and rotor to
housing clearances
2 Inadequate cooling water Check and clean coolers and
supply cooling water supply system
3 Excessive cooling water temp
4 Excessive discharge pressure
5 Compressor malfunction Check rotors for evidence of
rubbing. Reset clearances, if
necessary
8 Bearing temp high 1 Lube oil temp too high Clean and check lube oil
cooler
2 Loss of lubrication qualities in Drain and refill with new oil
lube oil
3 Lube oil pressure too high or Reset to proper operating
too low pressure
4 Bearing malfunction Disassemble, remove and
inspect hot bearing
5 Excessive pressure rise across Correct faulty inlet or
compressor discharge pressure controls
9 Compressor vibrates 1 Rotor rubbing due to loss of Replace worn parts and adjust
clearances rotor to rotor and rotor to
housing clearances
2 Piping improperly supported Apply necessary supports
3 Coupling misalignment Realign
4 Improper foundation
5 Improper grouting
10 Low lube oil pressure 1 Malfunction in lube system Check complete lube system
alarm and shutdown and adjust or replace
components where necessary
2 Malfunction of switch Adjust or replace switch

3 Excessive drop through lube Remove and clean filters
oil filters

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DOs and DONTs

DOs:
1. Check for oil and water leakage through the compressor.
2. Check functioning of stand by lube oil pump periodically.
3. Monitor bearing temperature trend regularly. If it is increasing substantially over a
period, there could be some problem with the bearings.
4. Follow SOPs and SMPs while overhauling the compressor
5. Remove temporary wire screen before putting compressor in service
6. Monitor amount and quality of oil in the drain lines. This helps in checking for
seal leakage.
7. Ensure that process shut off valve and bypass valve are open before starting
compressor.
8. Start seal buffering gas and cooling water supply before starting compressor.
9. Always ensure all start-up permissive like lube oil pressure / temperature, process
gas suction pressure / temperature, suction /discharge valve opening etc. are
fulfilled before start up.
10. Ensure all operating parameters are within operating window as specified in the
data sheet.
11. Ensure functioning of all the protective devices for safe operation of machine.
12. Monitor regularly lube oil level in the sump and top up if required.
13. Always ensure proper grade of oil is being topped up as recommended by OEM.
14. Ensure proper guards are mounted on the machine that no rotating parts are
directly exposed.
15. Ensure draining and purging of the machine before taking it into maintenance.
16. Use proper PPE when working on the machine.
17. Use proper certified tools & tackles while working on machine.

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DONT’s
1. Do not start the machine without understanding the control, protective and
monitoring system.
2. Do not start dismantling the machine without understanding dismantling

procedure.
3. Do not disable or bypass any protection for the machine without understanding
the consequences.
4. Do not change any alarm or trip value setting without concerning the experts.
5. Do not use used lubrication oil for topping up or for fresh charge.
6. Do not start maintenance work if the machine is not properly isolated.
7. Do not leave anything like spanners / bolts / cotton waste etc. inside the machine
or piping when machine is boxed up.
8. In the event of an emergency shutdown, while the unit is operating, do not attempt
to restart the unit until it bars over freely.

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FAQS
Q: What are the benefits of screw compressors over reciprocating compressors?

A: Screw compressors can handle dirt and fouling services whereas recip
compressors can not.
Q: What are the advantages of wet screw compressors over dry screw?
A: Wet screw compressors offer higher pressure ratios in comparison with dry screws
Q: What are the main application areas of screw compressors?

A: Screw compressors are widely used in air, refrigeration and process services
Q: How much reliable screw machines are?

A: Being rotary in motion, these machines have fairly very high reliability in
comparison to reciprocating compressors.
Q: How metal to metal contact is avoided in dry screw compressors?

A: Timing gears are used to synchronise the motion of two rotors; which prevents
contact of two screws.
Q: How wet screw compressor is different than dry screw compressor?

A: Oil is injected in the process gas for the complete compression process in wet
screw compressors.
Q: What type of bearings are employed in screw compressors:

A: Smaller machines may be fitted with antifriction radial and thrust bearings. Larger
machines have shell type heavy duty journal bearings combined with tilting pad
type thrust bearings.

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Q: How are bearings lubricated in large screw machines?

A: Bearings are lubricated with the use of pressure lubrication system
Q: In what category screw compressors belong?

A: Screw compressors are positive displacement type of machines
Q: What type of seals would be used for air compressors?

A: Labyrinth seals or carbon bushing are used for end seal in air/ inert services.
Q: What type of seals are employed in process services?

A: Mechanical contact seals are generally used for process services.
Q: How is oil separated in the wet screws?

A: Majority of the oil can be recovered via gravity simply by reducing the velocity of
the mixture and with appropriate changes in direction of flow. Impingement packs
and coalescors are also used to enhanced recovering.
Q: What are the main screw compressor manufacturers?

A: Howden, Manturbo, Kobelco, York, Atlas Copco, AC compressor, KPC etc are
the principle manufacturers of screw machines.

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TRAINING RELIANCE MODULE NO.

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TRAINING MODULE OBJECTIVE

• Introduction to screw compressors

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No part of this document may be reproduced in any form, in an electronic retrieval

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SECTION DESCRIPTION PAGES

2. Constructional features 20-25

3. Capacity control 26-31

4. Performance characteristics 32-34

5. Auxiliary equipment 35-42

6. Operation and maintenance guidelines 43-49

7. Condition monitoring 50-52

9. DOs and DONTs 56-58

10. FAQs 59-61

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INTRODUCTION TO SCREW COMPRESSORS

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1.2 SCREW COMPRESSOR TYPES

OIL FREE OIL INJECTED

DRY LIQUID MEDIUM HIGH

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1.2.1 DRY OIL FREE COMRPESSORS:

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1.2.2 LIQUID INJECTED COMPRESSORS:

Compression is accompanied by volume reduction and increase in temperature This

1.2.3 OIL INJECTED SCREW COMPRESSORS:

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1.3 FUNDAMENTALS OF OPERATION

A screw compressor is best described as a positive displacement volume reduction

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Volume ratio is a fundamental design characteristic of all screw compressors. The

where, Vi: Volume ratio or index

where, Pi: Internal pressure ratio

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2.1 SCREW COMRPESSOR ROTORS:

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2.4 TIMING GEARS:

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Large screw machines, as in case of centrifugal or reciprocating machine, do require

♦ LUBE OIL SYSTEM