SCREW

COMPRESSORS:
MISCONCEPTION
OR REALITY?

A Discussion of the Application and

Operation of Oil Flooded Rotary Screw
Compressors and A Comparison to the
Conventional Reciprocating Machines

Trent Bruce | NEXT Compression Corp.

Rocky View, Alberta, Canada | [Link]
 TABLE OF CONTENTS

ABSTRACT................................................................ 3

INTRODUCTION........................................................ 4

APPLICATIONS......................................................... 5

FEATURES OF THE SCREW COMPRESSOR............. 6

BASIC OPERATING PRINCIPLES.............................. 7

The Compression Process............................................ 7

Volume Ratio.................................................................. 9

Capacity Control............................................................. 11

Screw Compressor Package Components................... 14

CONCLUSION........................................................... 15

Acknowledgments
NEXT Compression would like to thank Frick and Ariel Corporation for their co-
operation in providing some of the graphics and information presented in this
paper. Their assistance in building this paper is greatly appreciated.

2 ScrewCompressors
 ABSTRACT
Screw compressors have been used on air and various
refrigeration and process applications for a great number
of years. In the past 20 years the machines have become
very popular in the natural gas industry in booster and gas
gathering applications with additional growth in the solution
gas market in recent years. Declining field pressures are
forcing the industry to look at more flexible alternatives to the
conventional reciprocating compressor. In addition to this,
many governments and environmental groups in North America
and around the world are pushing the industry to conserve
gases that have typically been vented into the atmosphere in a
variety of solution gas applications.
This paper will discuss specific applications where screw
compressors are used and the advantages of the rotary screw
to conventional reciprocating machines. We will look at some
specific features of the screw compressor, which make it
the machine of choice for many applications requiring high
reliability, low maintenance costs and a very wide overall
operating range.
We will look at a graphic model of a typical process flow
diagram and review the components required to make up a
rotary screw compressor package. We will also take a detailed
look at the internals of the machine to better understand the
overall operation, capacity control system, and the associated
power savings that go with it.
It some cases it is extremely important to optimize adiabatic
efficiencies in order to provide reduced power costs. On rotary
screw compressors this is done using a feature called Vi,
or internal volume ratio. The Vi can be changed on different
machines using a couple of different methods. We will compare
both these methods and their associated advantages.
Project economics always play an important role in any
equipment selection. With the proper flexibility built into
the initial package, these units can be used on numerous
applications.
In review, this paper will provide a detailed look at screw
compressors, where they are applied and exactly how they
operate. We will compare the rotary screw to other types of
machines for similar applications and show the benefits in
using this type of machine.

3 ScrewCompressors
INTRODUCTION
Oil flooded rotary screw compressors have been widely used on various
air and refrigeration applications for over fifty years. These machines did
not make a significant presence in the natural gas industry until the early
1990’s. Until this time, reciprocating compressors had been used almost
exclusively for natural gas compression. As gas fields have matured and
field pressures have dropped, screw compressors have become a very
attractive alternative and supplement to reciprocating machines.
This paper will discuss some of the applications and features of screw
compressors, basic operating principles and the advantages of the
rotary screw over conventional reciprocating compressors for the natural
gas compression industry. We will look at the machine itself, as well
as the overall compression system and the components required in a
screw compressor package. The screw compressors we will focus on
are the oil flooded, heavy duty process gas machines rather than the air
derivative types. We will provide numerous illustrations to help better
understand the screw machine.
Figure 1 shows the basic geometry of the rotary screw compressor.
View (A) is a simple representation of the actual rotors. We have labeled
the male rotor lobe and the female rotor flute. As the rotors turn in an
outward direction, the male lobe will unmesh from the female flute on the
top of the rotors forming an area for the gas to enter. The gas becomes
trapped in the machine and compression occurs when the lobes of the
rotors begin to mesh together again along the bottom. The shaded area
represents the pocket of gas that occurs within a specific flute. View (B)
is a representation of the side view inside the machine. The same flute
is shaded for comparison. Here we see the suction port in the upper
left corner and the discharge port in the lower right corner. The rotors
will turn in an outward direction forcing the male and female flutes to
unmesh, allowing process gas to enter the top of the machine. The gas
will travel around the outside of the rotors until it reaches the bottom
where the compression actually occurs. Gas will be discharged in the
lower right corner of the picture.

Figure 1

4 ScrewCompressors
 APPLICATIONS
As compressor manufacturers continue to increase the operating ranges of
their machines, many heavy duty screw compressors built today are capable
of suction pressures around 150 psig and discharge pressures up to 450 psig.
There are some screw compressors capable of operating at much higher
pressures by using cast steel casings but these are not commonly used in the
natural gas industry due to capital cost and availability so they will not the focus
of this discussion.
Screw compressors are commonly used in a variety of process gas, process
refrigeration and natural gas applications, including individual wellhead
boosters, low pressure gathering systems, low stage boosters to existing
reciprocating machines, fuel gas compression, solution gas and vapor recovery
compression systems. They have been used on sweet and sour gas as well as
acid gas applications with H2S and/or CO2 concentrations in excess of 80%.
Although most conventional natural gas applications are based on a specific
gravity of 0.57 – 0.65, screw compressors can be used on very light gases
such as hydrogen and very heavy mole weight gases with specific gravities
approaching 2.0.
Until quite recently, many people considered screw compressors limited to
sweet, dry natural gas applications. With changing regulations around the
World, we have seen screw compressors become much more common for the
unconventional gases because of their wide operating range and turndown
capability as well as the reduced maintenance costs. The biggest concern
people have is potential oil contamination when screw compressors are applied
in heavy, hot and sour applications. A simple process simulation to review the
worst case suction and discharge pressures, maximum inlet temperature and
the gas analysis can determine if a screw compressor can be applied in these
applications. The biggest issue is the need to ensure we operate the screw
compressor at a higher discharge temperature than the water and hydrocarbon
dewpoints. If our discharge temperature drops below the dewpoint temperature,
water and/or condensate will drop out during the compression cycle and
dilute the oil. Over time, this will eventually cause a catastrophic failure. Due
to the evolution of lubricants and a better understanding of screw compressor
operations, we can now provide machines that meet almost all of the low
pressure solution and treater gas applications we see.
The most common applications for screw compressors in natural gas service
range in horsepower from roughly 50 to 1,500 and are available in both engine
and electric drive. Screw compressors were originally developed to operate with
electric drive two pole motors at 3,550 rpm at 60Hz. As they have become more
popular in the natural gas industry, engine drive applications have become much
more common.

5 ScrewCompressors
FEATURES OF THE SCREW COMPRESSOR poor volumetric efficiencies, rod loading and
excessive discharge temperatures. In applications
where the system compression ratio exceeds
The rotary screw compressor is a positive displacement machine that operates four, multi-stage reciprocating machines will
offer better adiabatic efficiencies, or power
without the need for suction or discharge valves. It has the ability to automatically
requirements, than the single stage screw
vary suction volume internally while reducing part load power consumption. Screw compressors. In this case the user must weigh the
compressors provide a much wider operating range and lower maintenance costs than
conventional reciprocating compressors. The machines are much smaller and create
In general, screw advantages of the screw machine to the power
savings of the reciprocating compressor.
much lower vibration levels than piston machines as well. compressors
Accommodates Wide Operating Ranges
are considered
The screw compressor can operate over a very
to provide very wide range with little or no changes required to
Reduced Maintenance to do automatically and therefore very seldom
The only significant moving parts in a screw used. Using an external bypass valve or a high reliability, the machine. This makes it very well suited to
the natural gas industry where flow rates and
compressor are the male and female rotors. suction pressure control valve consumes more resulting in lower operating conditions are often changing. Over
There are no valves, pistons, piston rings, power than reducing the flow rate of gas within
or connecting rods that require regular the machine. The ability to adjust capacity maintenance costs time, as reservoir pressures decline, reciprocating
compressors encounter rod loading or discharge
maintenance. With the elimination of the pistons, within the screw compressor is comparable to and reduced down temperature limits and require costly retrofits.
varying the stroke length and suction volume
rings and valves, annual maintenance costs
on a reciprocating machine. However, the time compared This entails changing cylinders, changing cooler
are reduced. It is not uncommon to operate
screws for several years without ever performing screw can vary capacity automatically where to reciprocating sections and re-staging the machine.
the reciprocating machine generally uses
any significant maintenance or repairs. When
variable volume pockets that are adjusted
machines. Smaller Package Sizes
comparing screw compressors and reciprocating Rotary screws provide high capacities with minimal
machines, it is important to consider manually while the machine is shut down and
de- pressurized. The turndown capability using installation space compared to reciprocating
maintenance costs in the overall project cost. machines. Based on a full speed design of 3,600
variable volume pockets is less than using the
Turn Down slide valve in the screw compressor. rpm, a very large screw machine can provide over
80 MMSCFD of gas based on a 100 psig suction
Screw compressors offer turn down capabilities
High Compression Ratios pressure. The physical size of the compressor is
up to 90% of full load with very good part
Screw compressors can operate from roughly much smaller than a comparable reciprocating
load power requirements. This turn down
2 to 20 ratios of compression on a single stage machine which will require numerous cylinders to
capability occurs within the machine and is
while maintaining high volumetric efficiencies. move the same amount of gas.
independent of external driver speed or gas
These efficiencies are achieved by injecting large
recycle controls. This makes the machine an Lower Vibration
quantities of lube oil into the machine during the
attractive alternative for areas where flow rates With only two major moving parts operating in
compression process. Oil is typically injected
and operating conditions are not constant. a circular motion, screws create much lower
into the machine at an approximate rate of 10-20
The capacity control can be handled manually vibration levels than reciprocating machines.
USGPM per 100 HP, which significantly reduces
or automatically to meet the exact demands With lower vibration levels, screw compressors
the discharge temperature of the process gas.
of the overall system. Controlling the flow do not require the same type of foundation as the
The oil is discharged with the process gas and
rate or volume of gas through the machine reciprocating machines, which can result in lower
will be removed later from the gas stream.
significantly reduces the need for an external installation costs.
suction pressure control, discharge to suction Reciprocating machines can operate at much
recycle or automatic driver speed control. These higher pressures than screw machines, but In general, screw compressors are considered
are the most common means of automatic are typically limited to roughly 4 ratios of to provide very high reliability, resulting in lower
capacity control on reciprocating machines as compression per stage. Multi-staging and inter- maintenance costs and reduced down time
internal capacity control is much more complex cooling these machines is required to prevent compared to reciprocating machines.

6 ScrewCompressors
 The Compression Process On a reciprocating machine, gas will continue
Most people are familiar with the basic to enter the cylinder until the piston reaches
operation of a reciprocating compressor using the end of the stroke, or bottom dead center
a piston moving back and forth in a cylinder and the suction pressure in the system equals
to create compression. To help understand the pressure in the cylinder. At this point
BASIC OPERATING PRINCIPLES the operation of a screw compressor, we will the suction valve will close and the input
volume of the cylinder is established. If we
compare the compression process to a piston
type machine. multiply the input volume of each cylinder
A rotary screw compressor is very simple in design. Some of the major by the number of cylinders and then by
components include one set of male and female helically grooved Let’s think of the male rotor lobe as a piston and the compressor rpm, we will establish the
rotors, a set of axial and radial bearings and a slide valve, all encased the female flute as a cylinder. On a reciprocating compressor displacement.
machine, as the piston begins to pull away
in a common housing. Figure 2 represents a typical cutaway of a rotary On a screw compressor, gas will continue to
from top dead center, the suction pressure
screw compressor. The slide valve can not be seen in this picture. It is enter each flute until the rotor lobes roll out
overcomes the pressure inside the cylinder,
a “V” shaped device located along the bottom of the machine between of mesh with each other. As the rotors finish
forcing the suction valve open and allowing
the male and female rotors. We will look at the slide valve in detail later unmeshing with each other, the flute passes
gas to enter. We need to remember that a
by the edge of the suction port, closing it off
in this paper. screw compressor does not have any suction
from the system. The point where the flute
or discharge valves. On a screw compressor, travels past the edge of the suction port is
as the rotors begin to unmesh the male rotor where the maximum volume of that flute
lobe will roll out of the female rotor flute. The occurs. This represents the suction volume
volume vacated by the male rotor will fill with of the flute. The suction volume is the volume
suction gas. As the rotors continue to unmesh, of trapped gas within the flute at the end of
the volume in each flute will increase. Figure the suction process. Multiplying the volume
3 shows a comparison of the beginning of the of input gas in the male and female flute
suction process on a reciprocating machine by the number of lobes on the male rotor
and a screw compressor. View (A) represents and then by the rotor rpm establishes the
a single acting reciprocating cylinder. View displacement of the screw compressor. Figure
(B) illustrates a top view from the suction end 4 shows a comparison of the reciprocating
showing the rotors unmeshing and allowing the and screw machines at the end of the suction
gas to enter. View (C) shows a side view of the process. Once again, view (A) represents the
screw compressor at the same point. We can reciprocating cylinder, view (B) and (C) are the
only show the rotor closest to you as the other screw compressor. The volume of trapped
one is hidden. In order to keep the illustrations gas in the cylinder is still at suction pressure
simple, we will only show one rotor flute in because the compression process has not
operation. begun yet.

Figure 2

Figure 3 – Beginning of Suction Process Figure 4 – End of Suction Process

7 ScrewCompressors
Once the suction process is completed and the location of the discharge port along the axis will re-expand during the next suction tip of the rotor opens to the radial cut out area
input volume is established, the compression of the rotors is critical as it determines when process. This will reduce the amount of gas in the slide valve as shown in Figure 6 above.
process can begin. Figure 5 shows the same the compression process is complete, and the entering the cylinder, causing a reduction in The axial port will relieve the last bit of trapped
comparison of the reciprocating and screw discharge process begins. If we look at the volumetric efficiency of the machine. On high gas and lube oil from the rotors as the male
machines during the compression process. On individual flute containing the trapped gas we compression ratio applications, this will cause lobe completely fills the female flute, closing
the reciprocating machine, the piston begins see two rotor lobe tips, one on the discharge a significant decrease in efficiency, resulting in the threads as shown in Figure 7 above.
to move upward away from bottom dead side of the flute and one on the backside of the reduced flow rates.
In Figure 8 we can see the radial discharge port
center, reducing the volume in the cylinder and flute. The tip on the discharge side is called the
The discharge process on a screw compressor machined in the slide valve. The view is from
causing an increase in pressure of the trapped leading tip, as it will be the first one to reach the
will continue until the male rotor lobe has the discharge end of the compressor with the
gas. Here the screw compressor is not unlike discharge port. The second tip is referred to as
completely rolled into the female flute, rotors removed from the casing. The two bore
the recip machine. As the rotors continue to the trailing tip. Figure 6 shows the leading and
displacing all of the gas and lube oil remaining holes will normally form the casing around the
rotate, they begin to mesh together along the trailing tip of the rotor lobes. As the leading tip
in the threads. Unlike the reciprocating rotors. In Figure 9 we can see the rotor housing
bottom. Once again, let’s think of the male of the rotor passes by the edge of the discharge
machine, there are no trapped pockets of gas of the machine with the discharge end casing
rotor lobe as a piston and the female flute as a port, the compression process is complete and
remaining in the machine. As a result, the attached. The top half of the rotor housing has
cylinder. As the rotors mesh together the male the gas will be forced into the discharge line.
volumetric efficiency of a screw compressor been cut away to show the internals. As you
rotor lobe moves into the female flute and We saw how the suction volume of the can see, the ports are common to the discharge
remains very high as pressure differentials
reduces the volume in the flute. View (B) now compressor was established in Figure 4. flange of the compressor. They are defined
across the machine increase.
shows the bottom of the rotors to illustrate The discharge volume of the machine is differently because they each serve different
where the compression occurs. Keep in mind, the volume of gas trapped in the flute just Figure 7 provides a comparison of the purposes.
we are still looking at the rotors from the before the leading tip of the rotor enters the reciprocating and screw machines at the
suction end. The compression will continue as discharge port. Figure 6 shows a comparison completion of the discharge process. In
the gas moves toward the discharge port. View of the reciprocating machine and the screw View (B) we are still looking at the bottom
(C) shows the volume in the flute beginning to compressor at the beginning of the discharge of the rotors, but we are now looking from
reduce through compression. process. the opposite end. All of the previous rotor
pictures have been from the suction end of the
machine. We are now looking from the bottom
at the discharge end of the rotors.

Figure 8 – Radial Port

Figure 5 – Compression Process Figure 6 – Beginning of Discharge

The compression process will continue in The discharge process will be completed
the reciprocating machine until the internal on a reciprocating compressor when the Figure 7 – Completion of Discharge
pressure within the cylinder exceeds the piston reaches top dead center and the
discharge pressure of the system. At this point discharge valve closes again. There must Screw compressors have two discharge ports,
the discharge valve will open and allow the be a small clearance between the top of the referred to as the radial and the axial port.
trapped gas within the machine to escape. The piston and the head to avoid piston damage. The radial port is the “V” shaped cut in the
discharge process of a screw compressor is There will always be some inefficiency in the slide valve and the axial port is the butterfly
very different than a reciprocating machine. reciprocating machine due to this trapped shaped port machined in the end casing of the
There are no valves in the screw to allow pocket of gas left behind by the piston. The compressor between the bearing bores. The
discharge gas to escape from the flute. The volume of gas that remains in the cylinder discharge process will start when the leading Figure 9 – Axial Port

8 ScrewCompressors
 Volume Ratio Figure 10 shows two different slide valve
In the previous section we saw how the suction lengths to give a comparison of a low volume
volume of the machine was based on the ratio machine to one with a high volume
volume of trapped gas within a flute as it closes ratio. Looking at the illustrations, the suction
off from the suction port. We also showed that gas will enter the rotors as they unmesh in
the discharge volume is the trapped volume in the upper left corner of the diagram. As the
the same flute just before discharge. The ratio rotors continue to unmesh, they will close
of suction volume divided by discharge volume off from the suction port and establish the
is referred to as the volume ratio, or Vi, of a input volume, shown in blue. As the rotors
compressor. turn, the trapped gas is forced towards the
discharge end of the machine. The volume of
The position of the radial discharge port along the trapped pocket of gas will reduce until the
the axis of the rotors will determine the volume leading tip of the rotor passes by the radial
of gas in the trapped pocket at the point of discharge port. This is when the discharge
discharge. Moving the radial discharge port process begins. View (A) shows a low Vi
along the axis will change the effective stroke compressor with a short slide valve. As you
length of the rotors, changing the volume ratio. A can see, the stroke length is short resulting
low Vi compressor will provide a shorter effective in a higher volume in the flute as it passes the
stroke length than a high Vi machine and vice radial discharge port. View (B) shows a high
versa. A low volume ratio machine has a higher volume ratio machine with a longer stroke
volume of gas at the point of discharge than a length. The volume in the flute at the point of
high Vi machine. The suction volume is the same discharge is lower than the machine in View
in both cases. Dividing the suction volume by the (A), resulting in a higher Vi.
discharge volume will result in a lower volume
ratio in this case.
The volume ratio, or Vi, on a screw compressor
directly effects the internal compression ratio,
or Pi, of the machine. A low Vi compressor
corresponds to a low compression ratio machine.
High Vi compressors are used on higher
compression ratio systems. Figure 10 – Vi Comparison

The relationship between volume ratio and compression ratio is as follows:

Pi = Vik or Vi = Pi1/k , where k = ratio of specific heats, typically 1.26 – 1.3

Volume ratio and compression ratio are calculated using the following formula:
Vi = Vs/Vd, where Pi = Pd/Ps, where

Vi = Internal volume ratio; Pi = Internal compression ratio;

Vs = Internal suction volume; Pd = Internal discharge pressure, (psia);
Vd = Internal discharge volume. Ps = Internal suction pressure, (psia).

9 ScrewCompressors
Different manufacturers offer different volume The volume ratio of a compressor is very valve/slide stop moved into the minimum
ratio machines. The most common Vi range on important. We know the compression Vi position. Example (B) shows the same
a screw compressor is from 2.2 to 5.0. There process will continue until the flute is machine with the slide valve/slide stop
are some machines offered outside this range opened to the discharge port. If we operate assembly moved to the maximum Vi position
for special applications, but this is the most a high Vi compressor on a low compression for high compression ratio requirements.
common. Table I provides a comparison of ratio application, we will encounter over
Other manufacturers provide “Fixed Vi”, where
compression ratios and their corresponding compression. This means the discharge
different slide valves are available to meet the
ideal volume ratios based on the formulas pressure within the machine is higher than
provided above. the system discharge pressure. If we apply a
various requirements. On fixed Vi machines, The volume ratio
the slide valve will need to be changed
machine with a Vi of 5.0 to a system with a
out to achieve a more optimal Vi for the
of a compressor
compression ratio of 3.0 we will see extreme
over compression. From Table I above, we see
system. Most manufacturers offering fixed Vi is very important.
Table I – Vi Table
a compressor with a 5.0 Vi corresponds to an
machines will provide three or four different We know the
slide valves to meet the varying requirements.
Compression Ratio Ideal Vi Ratio
internal compression ratio of roughly 8:1.
The fixed Vi method limits the number of compression
Looking at a specific example, let’s use actual settings that can be achieved. On process will
2.0 1.7 a system suction pressure of 25 psia these machines we need to pick the Vi that
and a discharge pressure of 75 psia. The provides the closest ratio to our system continue until the
2.5 2.0
compression ratio of the system is 3:1. requirements. flute is opened to
The ratio within the machine is 8:1, which
3.0 2.3
equates to an internal discharge pressure
Figure 11 shows a comparison of the same the discharge port.
machine with two different slide valves for
3.5 2.6 of eight times the suction pressure, or 200
different Vi settings. View (A) is the low Vi If we operate a high
psi, when the leading tip of the flute reaches
4.0 2.9 the radial discharge port and allows the gas
machine where View (B) represents the high Vi compressor on
Vi compressor. Notice how the cut in the
4.5 3.2 to escape. In this application, we would see
slide valve in View (A) is deeper, resulting
a low compression
an approximate power penalty of 40% due
5.0 3.4 to over compression. Although the power
in a shorter stroke length and a lower ratio application,
compression ratio. These illustrations are not
penalty resulting from under compression
drawn to scale and are intended to assist in
we will encounter
5.5 3.7 is not quite as extreme, it is still significant.
understanding the concepts being discussed. over compression.”
From this we can see the importance of
6.0 4.0
maintaining a volume ratio in the compressor
6.5 4.2 that provides an internal compression ratio as
close as possible to the system requirements.
7.0 4.5
The volume ratio of a machine can be
7.5 4.7 changed using several different methods.
Some compressor manufacturers offer
8.1 5.0 “Variable Vi”, which means the slide valve/
8.5 5.2 slide stop assembly can be moved along
the axis of the rotors. This feature provides
9.0 5.4 an infinite number of Vi settings, within the
available range, to obtain the closest internal
9.5 5.7 compression ratio to the system ratio. If we
refer back to Figure 10, we see an example
10.0 5.9
of a machine with variable Vi by moving the
The above values were calculated using a “k” slide valve/slide stop. Example (A) shows
value of 1.3. the low volume ratio machine with the slide Figure 11 – Fixed Vi Machine

10 ScrewCompressors
 Capacity Control Figure 12 shows a compressor at full
Capacity control on a screw compressor package capacity and at minimum capacity. The large
can be handled using several different methods. flute volume represents the maximum input
The first, and most significant is internal to the volume as seen before. As we move the slide
machine and provides the reduction of flow valve away from the stop we open an internal
using the slide valve. This method is exclusive recirculation slot back to the suction port.
to the screw compressor and is not available Here the rotors have nothing to seal the gas
on reciprocating machines. As an alternate, against so no compression work is done.
reciprocating machines offer variable volume The compression process can not begin until
control pockets, VVCP’s, for internal capacity the flute has something to seal against. For
control within the machine, but these do not offer the purpose of illustration, we have brought
the same flexibility as the slide valve and cannot the slide valve in front of the rotor so we can
typically be controlled automatically. illustrate the movement and recirculation
slot. In reality, it would be located between
Up to this point, we have seen how the the rotors and we would not be able to see it
axial position of the slide valve along the as well.
rotors controls the volume ratio of a screw
compressor through the position of the radial
discharge port. The slide valve is also used to
control the throughput of gas in the machine.
It can provide up to 90% turndown, depending
on manufacturer and machine sizes. The major
significance to unloading with the slide valve is
the power savings that are associated with the
reduced flow rates.
In Figure 11 above, we saw how compression will Figure 12 - Capacity Control
occur along the bottom of the rotors beginning
on the left side, or suction end of the machine. The position of the slide valve can be
In all of the examples we have reviewed, the controlled automatically or manually to
compression process was able to continue all provide an infinite number of positions. This
the way from the suction end of the machine gives the machine the ability to flow the
through to discharge without interruption. We exact amount of gas required by the process.
have also seen how the maximum suction A hydraulic piston, located at the suction
volume of a flute occurs when the rotors end of the machine, is used to move the slide
completely unmesh from each other and close valve back and forth. A pressure sensor is
off from the suction port. used to monitor either suction or discharge
pressure. This sensor will indicate whether or
Now we will see what happens if we open up not the machine is operating above or below
an internal pocket along the bottom of the the set point.
machine just as the compression process
is about to begin. If we move the slide valve Let's look at an example where the screw
towards the discharge end of the machine, we compressor will discharge directly into two
open an internal recirculation slot for the gas to reciprocating machines in parallel. The
vent back to the suction port. This results in a screw compressor will be sized to meet the
lower suction volume of gas within the machine combined flow requirements of the piston
when the compression cycle begins. machines at a fixed suction pressure range.

11 ScrewCompressors
 compression ratios. At low ratios, the offload
Part Load Performance Curve (Based on a Frick 283S @ 1800 rpm) power consumption is better than the high
ratio machines. These power savings are
significantly higher than reciprocating
10 0
machines.
90
80 Other methods of capacity control on a
70 compressor package, (screw or recip), include
% Power 60 reducing driver speed, discharge to suction Driver speed
50 bypass, and inlet pressure control. These is the most
40 three methods are external to the compressor
30 itself and can provide some drawbacks. effective means of
20
On engine drive units, speed reduction is capacity control
10
0
typically limited to roughly 20-25% turn down on a compressor
in order to provide constant torque. Speed
01 02 03 04 05 06 07 08 09 01 00
reduction on electric drive units is done package as it
% Compressor Capacity using a variable frequency drive, which is reduces flow and
very costly. Please note that driver speed is
8.0 C. R. 5.0 C. R 3.0 C. R. Idea l the most effective means of capacity control power at a 1:1 ratio
on a compressor package as it reduces with speed.”
Figure 13 – Part Load Power Curve at Various System Compression Ratios flow and power at a 1:1 ratio with speed.
Discharge to suction bypass can provide
100% turndown but there are no power
savings associated with the reduced capacity
Let's look at the same example we looked at machine. This will reduce the throughput of because all the gas is still being compressed.
previously. We will use a suction pressure of gas in the compressor until it reaches the Cooler sizing must also be considered when
25 psia, a discharge pressure of 75 psia and desired pressure setting of 75 psia which will using bypass as capacity control. Typically
a flow rate will be 10 MMSCFD. This means equate to 5MM required by the recip machine. the machines are designed for suction
the reciprocating machines will provide a total temperatures in the range of 60-80oF, but
Once the down stream compressor is started
flow of 10 MM at 75 psia suction pressure, during bypass operation the gas will return
up again, the discharge pressure will begin
or 5 MM per machine. In this application to the compressor suction at roughly 120oF,
to fall as the reciprocating machines take
we will typically control the capacity of or whatever outlet temperature the gas
away the gas. The pressure sensor will
the screw compressor by monitoring the cooler was designed for. This will cause high
provide a signal to load the machine and oil
discharge pressure. In the event that one of temperature problems within the machine.
will be pumped through another port on the
the reciprocating machines is shut down, The last method of automatic capacity
directional valve back to the other side of
the screw compressor will need to unload or control is a suction pressure control valve.
the piston, forcing the slide valve towards
reduce the flow rate by 50% to prevent the This method is also inefficient from a power
the suction end until the desired pressure
reciprocating machine from overloading the standpoint. The suction pressure of the gas
is reached. If you are unsure of where the
engine. The discharge pressure sensor will must be reduced, and then re-compressed
hydraulic cylinder is located, please refer back
sense an increase in the discharge pressure again. On larger compressor packages, the
to Figure 2 earlier in the paper.
and send a signal back to the control system most common means of capacity control
telling it to unload the machine. Lube oil Operating at half capacity as we saw in the uses engine speed first, followed by slide
from the system will be directed through a above example provides significant power valve, then bypass for up to 100% turndown.
four way directional valve to the backside of savings as well. Figure 13 below shows Suction control is not a common means of
the hydraulic piston, forcing it to move the the typical part load power consumption capacity control on screws as it is the least
slide valve towards the discharge end of the of a screw compressor at various different efficient method.

12 ScrewCompressors
Lube Oil System The oil cooling can be done using two different
As we mentioned at the beginning of this methods. The direct cooling method simply
paper, the machines we are looking at are uses a section in the aerial cooler to cool the
oil flooded compressors. These machines oil using the ambient air. The indirect method
require lube oil to provide sealing between the cools the oil in a shell and tube or plate and
rotor lobes and the casing, and the male and frame cooler. A water/glycol mixture is pumped
female lobes where the compression occurs. through the other side of the exchanger and
The oil is also required for lubrication of the then circulated through a section in the aerial
bearings and shaft seals, and to reduce the cooler. This method requires an additional
heat of compression in the machine. exchanger and water pump.

The lube oil system on a screw compressor There are various arguments supporting each
is a closed loop system. The oil is injected method. We have found the indirect cooling
into the machine in several places. The to be the most useful in our applications. It
main oil injection port feeds the rotors is particularly important to use this method
directly with smaller lines feeding various in areas where cold ambient temperatures
points on the machine for seals and occur and the units are provided in heated
bearings. Once the oil is injected, passages buildings rather than outside. Here the oil
within the machine will drain all the is kept inside the building and not exposed
bearing and seal oil into the rotors where to freezing temperatures. Direct cooling
it combines with the gas. The gas and methods are not effective in cooler climates.
oil mixture is then discharged out of the Any oil left in an aerial cooler in cold weather
machine. The oil that is injected must be during shut down periods will become more
removed from the gas down stream of the viscous and difficult to move around the
compressor. system. In areas where the temperatures
are warmer, direct cooling methods are seen
A separate oil separator vessel is required more often. In these applications, vendors
to remove this oil from the gas. This vessel much choose the most effective and reliable
can be either vertical or horizontal in design, methods for their clients. Although additional
depending on equipment layouts and oil coolers and water pumps are required on
availability of space. The vessel will require the indirect systems, the cost of the aerial
coalescing type elements to remove as much cooler increases with direct cooling as oil
oil as possible. Typical oil carry over rates requires more surface area in the cooler than
from the separator are in the 10 ppm range. a water/glycol mixture and the oil section
The oil separator also acts as a reservoir is now required to be an ASME registered
for the lube oil system. The lube oil will flow higher pressure section as opposed to a
from the bottom of the separator, through an low pressure glycol circuit. Another factor
oil cooler where it is cooled from discharge we need to consider is the amount of oil in
temperature down to 140- 160oF, through the system. The direct cooling method will
an oil filter and then back to the machine. require much more lube oil than the indirect
Depending on the compressor manufacturer system. The oil used in these systems is
and the operating conditions, some machines typically a synthetic product that is much
require lube oil pumps to circulate the oil. more expensive than a water/glycol mixture.
Other manufacturers will use the differential Historically we have found the indirect oil
pressure from discharge to suction to move cooling to be the most common method in
the oil around the system. most parts of the World.

13 ScrewCompressors
 Figure 14 – Direct Oil and Direct Gas Cooling Figure 15 – Indirect Oil and Direct Gas Cooling Figure 16 – Indirect Oil and Indirect Gas Cooling

Screw Compressor Package Components injected into the bearings and shaft seal. The The indirect oil cooling system also provides separate from the ambient air inside a heated
With the exception of the oil separator and the remaining oil is injected directly into the rotors. some significant advantages in colder climates building and only glycol is circulated in the
oil cooling system, most of the components where heated buildings are often provided aerial cooler. Using a thermostatic valve on
The Process Flow Diagram in Figure 14 shows to keep the packages indoors and out of the the glycol circuit provides a constant glycol
on a screw compressor package are similar to
a direct oil and gas cooling system where the winter elements. This is a significant benefit supply temperature to the oil and gas coolers,
a reciprocating machine. Figure 14 provides
oil and gas are cooled directly in the aerial when ambient temperatures drop below eliminating the risk of the gas sections
a process flow diagram for a natural gas
cooler using ambient air. This system is freezing as it prevents the oil from being freezing off. This system is very effective in
screw compressor package. The inlet gas is
quite common in areas with warm ambient exposed to ambient air. A thermostatic valve applications where gas streams are water
fed through a suction scrubber, (V-1), or filter
conditions all year. It is typically a very cost is installed in the oil or glycol circuit to provide saturated at the inlet as the water will drop
to remove any free liquids and particulate.
effective method of cooling on smaller a constant warm oil supply to the compressor. out and freeze off in the direct gas cooling
Liquids are drained from the vessel to skid
edge and the gas is taken off the top and fed packages, (approx 400HP and below), but is Typically while the units are operating, the systems in cold weather.
into the compressor, (C-1), where it mixes somewhat limited to warm climates. In many direct cooling method works fairly well. The
cases, when the units get larger in size and When determining the most suitable cooling
with the lube oil. The high pressure gas and big concern happens when the units are shut
with higher oil volumes, an indirect oil cooling method for your application, it is important to
oil mixture is fed through the oil separator, down and the oil is sitting outside in the cooler
method may have some advantages. understand the year round ambient conditions
(V-2), where the oil is removed to accumulate exposed to cold temperatures. The oil becomes
you are dealing with, the size of the package
in the bottom of the vessel. The gas is then Figure 15 shows how we cool the oil indirectly very thick and needs to be heated up in order to
and the type of gas being compressed. In
sent to the after cooler, (E-1), where it is cooled using a separate plate and frame or shell and flow before the unit can be re-started.
short, the direct oil and gas cooling system
back down to the desired outlet temperature. tube exchanger. Here we require an additional Another cooling system that has proven very may be your best option if you are in a warm
The cooled gas is then taken off skid for glycol circuit in the aerial cooler as well as effective in areas with harsh winter climates climate with no risk of temperatures near
connection to the field piping. a glycol pump. In larger applications, this is the indirect oil and indirect gas cooling freezing and your compressor is smaller than
The compressor lube oil will flow from the may prove to be more cost effective as the system. Here, Figure 16 shows how we cool 400HP. If you are looking at a larger machine
bottom of the oil separator through an oil additional equipment costs can be offset by the oil and gas indirectly in plate and frame or and/or you will see some near freezing winter
cooler into the main oil header. This header replacing the high pressure oil section with a shell and tube exchangers. This system has conditions, the indirect oil cooling may be
splits into two main feed points for the low pressure, non-code section in the aerial proven to eliminate the risk of process system your most effective system. In areas with
compressor. Some of the oil is filtered, (F- cooler as well as reducing the amount of oil in freeze offs with ambient temperatures as harsh winters, the indirect oil and gas cooling
1), down to roughly 10 microns and then the system. low as -60oF. Oil and gas are kept completely systems clearly provide the most benefit.

14 ScrewCompressors
CONCLUSION
In recent years, declining pressures in
natural gas fields have made rotary screw
compressors a very attractive alternative
and supplement to reciprocating machines.
We know that screw compressors are
not designed to compete against the
reciprocating market in all applications.
Screws are lower pressure machines,
designed to operate up to roughly 400 psig
discharge pressure. They are not designed
to operate at the same high pressures that
piston machines can achieve.
Even with their growing popularity, very few
people understand how screw compressors
actually operate. We have looked at a
comparison of the compression process of a
screw machine to a reciprocating machine.
We have seen that screw compressors do
not have any suction and discharge valves
that open and close automatically based on
pressure differential across them. Screws
require proper positioning of the radial
discharge port to control volume ratio, which
is ultimately required to match the internal
compression ratio of the machine to the
system requirements.
We reviewed the concept of capacity control
using the slide valve, and the power savings
associated with the reduced capacity. We
have looked at the lube oil system, why it
is required, and how it operates. We also
reviewed the overall screw compressor
package and the different methods of oil
and gas cooling and reviewed the benefits
of each.
Screw compressors are not designed to
replace reciprocating machines. They
are designed to provide a very flexible,
highly reliable alternative for low pressure
applications.

15 ScrewCompressors
Trent Bruce | NEXT Compression Corp.
Rocky View, Alberta, Canada | [Link]