Rotary screw compressor

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Rotary screw air compressor internal view


Rotary screw air compressor in a housing for sound attenuation
A rotary screw compressor is a type of gas compressor which uses a rotary type positive
displacement mechanism. They are commonly used to replace piston compressors where large
volumes of high pressure air are needed, either for large industrial applications or to operate
high-power air tools such as jackhammers.
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.
Contents
[hide]
1 Operation
2 Size
3 Applications
o 3.1 Oil-free
o 3.2 Oil-flooded
4 Control schemes
o 4.1 Start/stop
o 4.2 Load/unload
o 4.3 Modulation
o 4.4 Variable displacement
o 4.5 Variable speed
5 Superchargers
o 5.1 Comparative advantages
o 5.2 Related terms
6 See also
7 References
Operation[edit]
Rotary screw compressors use two meshing helical screws, known as rotors, to compress the gas.
In a dry running rotary screw compressor, timing gears ensure that the male and female rotors
maintain precise alignment. 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 driving and driven rotor. 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.
[1][2]

The effectiveness of this mechanism is dependent on precisely fitting clearances between the
helical rotors, and between the rotors and the chamber for sealing of the compression cavities.
Size[edit]
Rotary screw compressors tend to be compact and smooth running with limited vibration and
thus do not require spring suspension. Many rotary screw compressors are, however, mounted
using elastomeric vibration isolating mounts to absorb high-frequency vibrations, especially in
rotary screw compressors that operate at high rotational speeds. Rotary screw compressors are
produced in sizes that range from 10 cubic feet per minute to several thousand CFM. Rotary
screw compressors are typically used in applications requiring more airflow than is produced by
small reciprocating compressors but less than is produced by centrifugal compressors.
Applications[edit]
Typically, they are used to supply compressed air for general industrial applications. Trailer
mounted diesel powered units are often seen at construction sites, and are used to power air
operated construction machinery.
Additionally, they are becoming increasingly popular in municipal wastewater treatment
facilities, for their increased efficiency and thus, lower power consumption.
[citation needed]

Oil-free[edit]
In an oil-free compressor, the air is compressed entirely through the action of the screws, without
the assistance of an oil seal. They usually have lower maximum discharge pressure capability as
a result. However, multi-stage oil-free compressors, where the air is compressed by several sets
of screws, can achieve pressures of over 150 psig, and output volume of over 2000 cubic feet
(56.634 cubic meters) per minute (measured at 60 C and atmospheric pressure).
Oil-free compressors are used in applications where entrained oil carry-over is not acceptable,
such as medical research and semiconductor manufacturing. However, this does not preclude the
need for filtration as hydrocarbons and other contaminants ingested from the ambient air must
also be removed prior to the point-of-use. Subsequently, air treatment identical to that used for
an oil-flooded screw compressor is frequently still required to ensure a given quality of
compressed air.
Oil-flooded[edit]


Diagram of a rotary screw compressor
In an oil-flooded rotary screw compressor, oil is injected into the compression cavities to aid
sealing and provide cooling sink for the gas charge. The oil is separated from the discharge
stream, then cooled, filtered and recycled. The oil captures non-polar particulates from the
incoming air, effectively reducing the particle loading of compressed air particulate filtration. It
is usual for some entrained compressor oil to carry over into the compressed gas stream
downstream of the compressor. In many applications, this is rectified by coalescer/filter
vessels.
[3]
In other applications, this is rectified by the use of receiver tanks that reduce the local
velocity of compressed air, allowing oil to condense and drop out of the air stream to be removed
from the compressed air system via condensate management equipment.
Control schemes[edit]
Among rotary screw compressors, there are multiple control schemes, each with differing
advantages and disadvantages.
Start/stop[edit]
In a start/stop control scheme, compressor controls actuate relays to apply and remove power to
the motor according to compressed air needs.
Load/unload[edit]
In a load/unload control scheme, the compressor remains continuously powered. However, when
the demand for compressed air is satisfied, instead of disconnecting power to the compressor, the
inlet valve is closed, unloading the compressor. This reduces the number of start/stop cycles for
electric motors over a start/stop control scheme in electrically-driven compressors, improving
equipment service life with a minimal change in operating cost. This scheme is utilised by nearly
all industrial air compressor manufacturers. When a load/unload control scheme is combined
with a timer to stop the compressor after a predetermined period of continuously unloaded
operation, it is known as a dual-control or auto-dual scheme.
[4]

Modulation[edit]
Instead of starting and stopping the compressor or actuating the inlet valve between two distinct
positions, a modulation control scheme proportionally adjusts the inlet valve open and closed,
altering the compressor discharge according to demand. While this yields a consistent discharge
pressure over a wide range of demand, power consumption is significantly higher than with a
load/unload scheme, resulting in approximately 70% of full-load power consumption when the
compressor is at a zero-load condition.
Due to the limited adjustment in compressor power consumption relative to compressed air
output capacity, modulation is a generally inefficient method of control when compared to
variable speed drives. However, for applications where it is not readily possible to frequently
cease and resume operation of the compressor (such as when a compressor is driven by an
internal combustion engine and operated without the presence of a compressed air receiver),
modulation is suitable.
Variable displacement[edit]
Utilized by compressor companies Quincy Compressor, Kobelco, Gardner Denver, and Sullair,
variable displacement alters the percentage of the screw compressor rotors working to compress
air by allowing air flow to bypass portions of the screws. While this does reduce power
consumption when compared to a modulation control scheme, a load/no load system can be more
effective when large amounts of storage (10 gallons per CFM). If a large amount of storage is not
practical, a variable displacement system can be very effective, especially at greater than 70% of
full load.
[5]

One way that variable displacement may be accomplished is via the use of multiple lifting valves
on the suction side of the compressor, each plumbed to a corresponding location on the
discharge. In automotive superchargers, this is analogous to the operation of a bypass valve.
Variable speed[edit]
While an air compressor powered by a variable speed drive can offer the lowest operating energy
cost without any appreciable reduction in service life over a properly maintained load/unload
compressor, the variable frequency power inverter of a variable speed drive typically adds
significant cost to the design of such a compressor, negating its economic benefits if there are
limited variations in demand. However, a variable speed drive provides for a linear relationship
between compressor power consumption and free air delivery. In harsh environments (hot,
humid or dusty), variable speed drives may not be suitable due to the sensitivity of the
equipment.
[6]

Superchargers[edit]


Lysholm screws. Note the complex shape of each screw. The screws run at high speed and with
closely engineered tolerances.
The twin-screw type supercharger is a positive displacement type device that operates by
pushing air through a pair of meshing close-tolerance screws similar to a set of worm gears.
Twin-screw superchargers are also known as Lysholm superchargers (or compressors) after their
inventor, Alf Lysholm.
[7]
Each rotor is radially symmetrical, but laterally asymmetric. By
comparison, conventional "Roots" type blowers have either identical rotors (with straight rotors)
or mirror-image rotors (with helixed rotors). The Whipple-manufactured male rotor has three
lobes, the female five lobes. The Kenne-Bell male rotor has four lobes, the female six lobes.
Females in some earlier designs had four. By comparison, Roots blowers always have the same
number of lobes on both rotors, typically 2, 3 or 4. The working area is the inter-lobe volume
between the male and female rotors. Its 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.
Comparative advantages[edit]
The rotary screw compressor has low leakage levels and low parasitic losses vs. Roots type. The
supercharger is typically driven directly from the engine's crankshaft via a belt or gear drive.
Unlike the Roots type supercharger, the twin-screw exhibits internal compression which is the
ability of the device to compress air within the housing as it is moved through the device instead
of relying upon resistance to flow downstream of the discharge to establish an increase of
pressure.
[8]

The requirement of high-precision computer-controlled manufacturing techniques makes the
screw type supercharger a more expensive alternative to other forms of available forced
induction. With later technology, manufacturing cost has been lowered while performance
increased.
All supercharger types benefit from the use of an intercooler to reduce heat produced during
pumping and compression.
A clear example of the technology applied by the twin-screw in companies like Ford, Mazda,
Mercedes and Mercury Marine can also demonstrate the effectiveness of the twin screw. While
some centrifugal superchargers are consistent and reliable, they typically do not produce full
boost until near peak engine rpm, while positive displacement superchargers such as Roots type
superchargers and twin-screw types offer more immediate boost.
Related terms[edit]
The term "blower" is commonly used to define a device placed on engines with a functional need
for additional airflow. The term blower is applied to rotary screw, roots-type, and centrifugal
compressors when utilized as part of an automotive forced induction system.
See also[edit]
Gas compressor
Guided rotor compressor
Reciprocating Compressor
Vapor-compression refrigeration
Variable-speed air compressor
References[edit]

Wikimedia Commons has media related to Screw compressors.
1. Jump up ^ Screw Compressor. Describes how screw compressors work and include photographs.
2. Jump up ^ Fundamentals of natural gas processing
3. Jump up ^ Technical Centre Discusses oil-flooded screw compressors including a complete system flow
diagram
4. Jump up ^ http://www.compressedairchallenge.org/library/sourcebook/compressed_air_sourcebook.pdf
5. Jump up ^ http://www.compressedairchallenge.org/library/sourcebook/compressed_air_sourcebook.pdf
6. Jump up ^ http://www.plantservices.com/articles/2006/288.html
7. Jump up ^ http://www.airends.com/LysholmArticle.htm
8. Jump up ^ Twin Screw vs. Roots supercharging, Kenne Bell











Air Compressor Working Principle
Working principle:
Air compressors collect and store air in a pressurized tank, and use pistons and valves to achieve the
appropriate pressure levels within an air storage tank that is attached to the motorized unit. There are
a few different types of piston compressors that can deliver even air pressures to the user.
Automotive compressors are combustion engine compressors that use the up-and-down stroke of the
piston to allow air in and pressurize the air within the storage tank. Other piston compressors utilize a
diaphragm, oil-free piston. These pull air in, and pressurize it by not allowing air to escape during the
collection period.
These are the most common types of air compressors that are used today by skilled workers and
craftsmen. Before the day of motorized engines, air compressors were not what they are today.
Unable to store pressurized air, a type of antique air compressor may be found in the blacksmith's
foundry bellows.
Now the air compressor is capable of building extreme pressures in storage tanks capable of storing
enormous amounts of pressurized gases for industrial use.

Capacity:
The capacity of an air compressor is determined by the amount of free air (at sea level) that it can
compress to a specified pressure, usually 100 psi per minute, under the conditions of 68F and a
relative humidity of 38 percent. This capacity is expressed in cubic feet per minute (cfm) and is
usually included in the nomenclature of the compressor.
The number of pneumatic tools that can be operated at one time from an air compressor depends on
the air requirements of each tool; for example, a 55-pound class rock drill requires 95 cfm of air at 80
psi. A 210-cfm compressor can supply air to operate two of the drills, because their combined
requirements is 190 cfm.
However, if a third such drill is added to the compressor, the combined demand is 285 cfm, and this
condition overloads the compressor and the tools and results in serious wear
Air Compressor Working Principle
Atlas Copco's GAe oil-injected rotary screw compressors are leader in the market thanks to outstanding performance and flexible
operation. This results in the highest productivity while minimizing the total cost of ownership.GAe compressors are available in two
series, GAe 11-30 and GAe 18-30 VSD. The GAe 11-30 is built to perform even in the harshest environments. The GAe 18-30 VSD
range is the optimal solution for productions with a fluctuating air demand, optimizing your energy consumption. Both ranges supply
the high-quality air you need to keep your air network clean and your production up and running.

Customer benefits
Highest reliability The GAe series is designed, manufactured and tested in accordance with ISO 9001, ISO 14001 and ISO 1217.
Ensuring a long and trouble-free life at the lowest operating cost. GAe compressors are equipped with the latest generation of Atlas
Copcos innovative oil-injected screw element integrated with a closed gear drive eliminating the need for a coupling suitable for the
harshest environment.
Reduced energy costs Our GAe compressors can reduce your energy costs and overall compressor lifecycle costs thanks to the
use of our highly efficient element. Furthermore, the GAe Variable Speed Drive (VSD) reduces energy costs by a further 35% by
automatically adjusting the air supply to your air demand with a large turndown operating range.

Air system integration - The GAe WorkPlace Air System can be installed where you need compressed air. Its low noise operation
and integrated air treatment equipment eliminates the need for a separate compressor room. All GAe compressors are tested and
delivered ready for use. The integrated options will reduce installation costs and pressure drops significantly, thus saving additional
energy cost.
Advanced control and monitoring Our compressor controller, Elektronikon, regulates and controls the entire compressor,
including all build in options. The Elektronikon ensures good operation of all components, controls drive motors and regulates
system pressure within a predefined and narrow pressure band. This results in low energy consumption and increase efficiency and
reliability of the compressor. The Elektronikon of the latest generation provides free online visualization, enabling you to monitor
your compressors status over the intranet.
Integrated purity All GAe compressors have integrated dryer, filters and oil-water separator available to protect your compressed
air network. This quality air expands the life of equipment, increasing efficiency and ensuring quality in your final product.

Technical data
Units:
Metric
Imperial
Technical Specifications
Capacity FAD (l/s) 13.2 - 80 l/s
Capacity FAD (m/h, cfm) 28 - 169.4 cfm
Working pressure 58 - 188 psig
Installed motor power
15 - 40 HP



Total customer care
Your bottom line, maximum availability of our equipment at minimum total operating cost, is the top priority for all of us at Atlas
Copco. Our way of achieving that builds on interaction, on long-term relationships and involvement in your processes, needs and
objectives.
Our organization and people are committed to the maximum operational availability and efficiency of your compressed air network.
Total customer care is our goal at any level of service interaction with you; from standardized genuine parts over tailormade service
plans to remote monitoring and optimization.
We want you to see Atlas Copco as a real performance partner that can contribute to the productivity of your processes. The best
way of taking care of your interest is by taking the best care of your equipment.

Save energy
With their detailed and extensive knowledge of compressed air, our energy and air consultant engineers will be able to determine an
acceptable operating balance, that is both within the capabilities of your compressors and also adequate to satisfy your production
with minimized operational running costs.

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advisors will visit your production facilities and assess your specific needs. This allows us to propose the most cost effective
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Because Atlas Copco genuine parts are built according to the same quality standards as your compressor, you are guaranteed that
your production, even after servicing your compressor, will remain at the same high level.

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We work with you to develop financing options that includes your choice of equipment
with related products and services. We make it easy when you do business with Atlas Copco.

Financing helps you to acquire your Atlas Copco equipment without impacting other lines of
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terms are flexible and tailored to suit your specific requirements and business forecasts.

We provide a wide range of financing solutions for all types of Atlas Copco equipment and
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various types of project financing.

Contact your Atlas Copco sales company to receive a proposal of monthly payments orcontact
us directly and we will tell you more about how we can support you















AIR COMPRESSORS (KPCL)

About KIRLOSKAR PNEUMATIC CO. LTD. (KPCL)
The name Kirloskar is synonymous with quality and dependability in the engineering industry. Pioneering industrial revolution in India,
Kirloskar group has contributed immensely in every field of its operation during its 120 year-long journey, and holds a place of repute in
the industry for its good business values and customer focus.
Kirloskar Pneumatic Company Ltd is in compressor business since 1955 & is one of the core group companies. The company started its
operations with the manufacture of Air Compressors and Pneumatic Tools. The company has also earned an enviable reputation for its
Systems Engineering and Turnkey Project expertise.
Over the years, Kirloskar Pneumatic Company Ltd. has developed various sophisticated and high-tech products in the above categories
to cater to the demands of various industrial sectors. KPCL has also established a number of joint ventures and technology partnerships
with leading global companies. It has earned the distinction of developing a host of advanced products to suit Indian conditions and has
been continuously updating them to maintain the highest standards of quality and reliability.
From a product manufacturer in the domestic market to a company offering total solutions from designing systems to manufacturing
customized products and systems, KPCL has come a long way. The customer-centric work culture along with technical excellence has
been the hallmark of this success. The graduation was steady and strategically aimed at specific market segments. Our ultimate reward is
a satisfied customer.
1. KIRLOSKAR ELECTRICAL SCREW COMPRESSORS
We manufacture these compressors in Skid Mounted Category with named KES 7 TO KES 11 (R1) KES 15 to KES 55 (R2 R3 range)
& KES 55 to KES 160 (R4 R5 range) & in Tank Mounted category with named as KES 7 to KES 11, with the pressure ranging from
7.5 kg/cmg to 13 kg/cmg & capacity from 1.87 m/min to 31.15 m/min.
Salient Features

Ready to use: No foundation is required.
Quality Air:
Efficient air / oil separation system ensures maximum oil recovery to minimise lub oil consumption and
maintenance cost.
Canopy: Specially designed silent canopy to facilitate effective ventilation and ease of maintenance.
Controller: Microprocessor based efficient controller with necessary safety control systems and maintenance schedule.
Cooling System:
Radiator type aluminum combi cooler with low noise fan & motor provided for effective cooling of lub oil
and compessed air.
Control Panel:
In built control panel housing MMI, controller, main motor auto star delta starter, fan motor direct on-
line starter & other control of the package.
Air suction filter: Dry type air filter protects the air end and ensures long life.
Electric Motor:
Highly efficient, TEFC, Class F insulation, Foot cum Flange mounting, 4/2P, EFFI, IP55 protection motor
is selected considering operating conditions at site.
Service Centres:
Fully equipped Service Centres with trained engineers and spare parts stocks available across
the country.

2. Diesel Engine Driven Portable Air Compressors
KPCL Diesel Engine Driven Portable Compressors are used for applications like construction & mining, General engineering etc. These
units cover a wide capacity range from 5 m/min to 17 m/min & pressure range from 7 kg/cmg to 10 kg/cmg.
Salient Features

Easy Portability: Large diameter wheels with balanced design of weight distribution facilitate easy portability
Quality Air:
Efficient air / oil separation system ensures maximum oil recovery to minimise lub oil
consumption and maintenance cost.
Canopy: Specially designed silent canopy to facilitate effective ventilation and ease of maintenance.
Controller:
Microprocessor based efficient controller with necessary safety control systems and
maintenance schedule.
Cooling System:
Radiator type aluminum combi cooler with low noise fan & motor provided for effective
cooling of lub oil and compessed air.
Control Panel:
In built control panel housing MMI, controller, main motor auto star delta starter,
fan motor direct on-line starter & other control of the package.
Air suction filter: Dry type air filter protects the air end and ensures long life.
Electric Motor:
Highly efficient, TEFC, Class F insulation, Foot cum Flange mounting, 4/2P, EFFI,
IP55 protection motor is selected considering operating conditions at site.
Service Centres:
Fully equipped Service Centres with trained engineers and spare parts stocks available
across the country.

3. KPCL Diesel Screw Compressors
KPCL Diesel Screw Compressors are the results of extensive know-how & experience of more than five decades in design,
manufacturing, supply & installation of various capacities & pressures.
Single Stage Diesel Screw Compressor :
A versatile range of Rotary Twin Screw air Compressors, with capacity range from 7 cubic meter per minute (250 cfm) to 25 cub ic
meter per minute (900 cfm) at working pressure up to 14 kg per square centimeter-gram (200psig).
Salient Features

Provision of efficient oil separators Light weight and compact
Minimum fuel consumption Specially design canopy
Lower water, lube oil & air delivery temperature Unique single lever unloading system


Two Stage High Pressure Diesel Screw Compressor:
KPCLs Two stage high pressure diesel screw compressor having normal capacity ranges from
28 m/min (1000 cfm) to 31 m/min (1100 cfm) at working pressure up to 17.5 kg/cmg
(250psig) to 21 kg/cmg (300psig).
Salient Features

Lower Power consumption; highly energy efficient
Efficient 4 stages Oil / Air separation system;
Clean air
Vibration free silent working Specially design canopy
Lower working temperature of oil, water & air Efficient synchronous step-less capacity control
Sturdy air cooled oil cooler with anti-vibration mounts Light weight and compact

4. Centrifugal Air Compressors
KPCL has a technical tie-up with Cameron Compression of USA for packaging and marketing Centrifugal Air Compressors in India.
Designed with a capacity up to 20,000 Cubic meter per hour, Camerons plant air series 3 stage, oil free, air compressor, finds its
application in power, steel, automobile, textile, general engineering, air separation and pharmaceutical sectors.
Salient Features
100% Oil-Free Air, hence higher product quality and lower operating cost.
Easy to maintain, no disassembly required, online element replacement facility.
Reliable & efficient operation.
Best specific power amongst any three stage compressors in its class.
Very low Life Cycle cost.
State-of-the-art, energy saving controls.
Deliver greater flow for every kW.
Salient Features

Features Benefits
Superior Pinion
Bearing Long service life and unlimited operating load.
Advanced lubrication
system Self contained, low pressure system.
Impellers Combine best features of semi-redial and backward leaning impellers.
Intercooler Easy removals without component dismantle.
Guide vanes
When system demand is less than 100%, capacity vanes reduce the air flow in to the air
compressor, reducing power consumption.
Maestro panel Ease-of-use and maximum operating efficiency.
Technical Data

Power Rating 150-2250 HP / 112-1680 kW
Discharge Pressure 5.5-10.3 bar. G /80-150 psig
Flow Capacity 15.6 334 m3/min / 550-11,800 CFM
Compressor Weight 5.443kg /12.000 lbs Typical (Motor Dependent)

5. After Sales Service & Spare Parts(KPCL)
Air Compressor Division (ACD) provides after sales service (for products in warranty & out of warranty) through Head Office and its
wide spread network of branch offices, channel partners, service franchisees.
The Spare Parts Division caters to the need of all spare parts of Vertical Reciprocating Compressors, Balance Opposed Piston
Compressors, Centrifugal Compressors, Screw Compressors, Railway Brake Compressors and exhausters, High Pressure compressors
used in Oil. This is further supported by a well spread Dealers Network all over India.
Our stockist dealers keep most spares & consumables. We can also offer spare parts against specific enquiry based on manufacturer part
numbers.




Applications: Suitable for General Engineering
Applications, Mining, Construction, Cement Plants,
Chemical industry, Steel Plants, Thermal Power
Plants, Automobile Industry, Air Separation,
Petrochemical and Fertilizer Plants, Gas Applications,
Sugar etc


SWOT Analysis
This free sample SWOT analysis shows strengths, weaknesses, opportunities and threats. We cover
over 40,000 companies and industries. This sample SWOT analysis for Kirloskar Group can provide
a competitive advantage.
Strengths

-existing distribution and sales networks

Weaknesses

-tax structure
-competitive market
-high loan rates are possible
-future competition
-unknown

Opportunities

-income level is at a constant increase
-growing demand

Threats

-unexpected problems
-increasing costs

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contact us for further information. We are not responsible for any errors or omissions on this page.
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