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Twin-Screw, Oil-Injected Screw Compressors Have Higher Compression Ratios,
Simplified Design, Efficient Operation and Greater Reliability Than Oil-Free Designs
By Amin Almasi
Screw compressors have many inherent advantages over The focus here is on the oil-injected type. The operating
other compressor types (mainly reciprocating and centrifu- principle of screw compressors has been known for over
gal) in the low- to medium-flow range. Since they are posi- 125 years. Despite serous efforts to produce them, they
tive displacement compressors, they will draw a constant were not made until low-cost manufacturing methods be-
inlet volume, can meet the varying differential pressure re- came available for accurate machining of the rotor profile
quirements and are not significantly affected by gas density (precision cutting and machining tools). Since then, great
or composition. improvements have been made in performance prediction,
Compared to reciprocating compressors, pulsations rotor profile and manufacturing techniques. They have
are considerably reduced, suction and discharge valves largely replaced reciprocating compressors and centrifugal
and troublesome unloaders as well as high maintenance compressors for many industrial and process applications.
packing are not required. Rotary motion significantly re- Fig. 1 shows screw compressor components including ro-
duces the footprint of the screw compressor unit com- tors and casing.
pared to other positive displacement alternatives. The
result is an efficient, reliable, simple and compact com-
pressor that is very competitive from an initial cost and
installed cost standpoint.
Two types of twin screw compressors are available, oil
free and oil injected (oil flooded). Although both types
use helical rotors (screws), many significant differences
can be identified between the two types. Oil-injected
screw compressors are the newest type. Compared to dry
type, oil-injected screw compressors enable much higher
compression ratios, simplified mechanical design (such as
eliminating the timing gears), more efficient operation and
greater reliability.
SOLVED
ing conventional carbon steel or grey cast iron as materials
of construction.
BOLTING
PROBLEMS
5. Oil acts as a noise damper. Combined with low rotor
lobe passing frequencies, this has the advantage that most
installations do not require extensive sound attenuation to
meet acceptable site noise levels.
Generally, grey cast iron may be suitable for pressures up
to 217 psi (15 bar). Steel and spheroidal graphite (SG) iron
casings can handle pressures up to 580 to 725 psig (40 to 50
bar). Refer to API 619 for material selection. Discharge pres-
sure of screw compressors is limited by various factors: 1.
Gas discharge temperature, 2. Rotor length-to-diameter ratio
(L/D ratio) and 3. Material and casing design.
Superbolts patented
stud/bolt Tensioners
Figure 2. Working mechanism of a twin screw compressor, form left eliminate unsafe and
to right: compression; entrapment and volume reduction; and dis- time consuming bolting
charge process. methods. Only hand/air
tools are required!
During the start of the suction stroke, gas enters the
flutes of the rotors. At the end of the suction stroke the suc- Learn More:
www.superbolt.com
tion port is sealed from the gas-filled flutes by the meshing
of the next lobe. The trapped gas is then briefly moved Request your FREE
axially along until the flutes reach the end wall and the 1-412-279-1149
1-800-345-BOLT (U.S.A.)
FREE DVD &
DVD or catalog
today!
continued on page 64 bolting@superbolt.com
Catalog available!
www.superbolt.com
ate at higher temperatures and are being used increasingly. see directlink At www.compressortech2.com
In the absence of reactive gases (oxygen, etc.) mineral oils
can operate at much higher temperatures though their vis-
cosity drops rapidly with rising temperature. Some synthetic
lubricants, with high viscosity indices, can be used over a Improve Performance,
Restore Efficiency
large temperature range. Factors to consider when selecting
the lubricant include: 1. Oxidation, 2. Condensation, 3. Vis-
cosity, 4. Out-gasing in the inlet, 5. Foaming, 6. Separation
performance, and 7. Chemical reaction.
Some of the problems can be solved with specially se-
lected oil grades. Cost is a problem with synthetic oils, par-
ticularly with silicon oils. Alternatives must be reviewed to
match service life of the lubricant with lubrication require-
ments. For chemical service, some lubricant qualities may
be sacrificed in order to obtain a fluid compatible with
the process gas. In these applications, alternative bearing Count on Foley Rebuild Centers trained technicians and
materials such as graphite or silver have been required. state-of-the-art facility to help you stay ahead of the game
While the requirements may make the operation somewhat and avoid costly engine downtime. We offer:
special and require considerable care, the life of the com-
pressor and service can be greatly improved. Complete Engine Rebuilds 24 Hr. Field Service
Dual-circuit oil-injected machines (separate oil circuit for Engines Available for Quality Machine Shop
compressor oil injection and bearings) can also be used for Exchange Emissions Analyzer Testing
applications with some special contamination. A separate G3304 to G3616 Capability 24 Hr. Parts Availability
lube oil circuit would more fully protect the bearing against Up to 5,000 HP Dyno
intrusion of contaminants, including the longer-term detri- Contact us today to learn more!
mental effects of H2S on steel element bearings, especially.
Based on experience, amply documented by the National
Association of Corrosion Engineers (NACE) and various com-
pressor manufacturers and users, a combination of hydrogen
sulfide, water, stress and hardened steel (RC 25 or higher)
will place the steel used in a rolling bearing element in the FOLEY REBUILD CENTER
100% failure range. A dual-circuit oil system is not common, 1601 E. 77th St. North Park City, KS (316) 943-4211
but it is the only available solution for reliable operation in www.foleyeq.com/rebuild
some special applications. 2010 Caterpillar All rights reserved. CAT, CATERPILLAR, their respective logos, Caterpillar Yellow,
continued on page 66 the Power Edge trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.