:

) , , ,(

Screw Compressors

.





Manual Book
Clark Atlas Copco API



Dynamic
.......
Screw Compressors

...
.



.

:

) (
:
- Fans
-Blowers
-Compressors
- Fans
) 300 (
.
:
- Forced Draft Fan
- Induced Draft Fan
Forced Draft Fan
) (
:
- .
- Fin Fan .
-
....

.

 Induced Draft Fan

.
.

.

) (
Make Up.
- Blowers

) ( 3 bar .

-Compressors


. 3 bar .


.
.


:
- Air Compressors
Instrument Air Plant

8 Bar.
- Make Up
200Bar
.
- Circulation

.
- LPG C3 C2 C1

.
- Nitrogen
Purging

.
-
.

-
.
The Behavior Of Gases


.
.
Gas Pressure
.

Pressure Guage ,
.

:
P=F/A
) (.........
) (......... .

1Psi .


) ( .
Atmospheric Pressure
.
/

.

) (
) ( .
) ( /
.

 :
-Gage Pressure
-Absoloute Pressure
Gage Pressure
, Gage Pressure
) (
Vacuum
. )( -/ .

Absoloute Pressure
) (
Absoloute Pressure .
:
Absoloute Pressure=Atmospheric Pressure+Gage Pressure
.

)(


:
-) (

-
-
.

 )(......
.... .
.

) ( .
-) (


.
:
2
V
2g
V g
.
:

:

) ( .
V = 2 gH

H .
-

)
.

Gas Temperature
.

.
) (
.
)
(

 ) ( ) (
.
:
- Gage Temperature
- Absolute Temperature
Gage Temperature

. ) (

.

Absolute Temperature

.
-
.

 :
K=C+273.16
Rankine
:
R=F+460
:
)C=5/9(F-32
.

 Gas Volume

Cubic Foot,
.......... .
.
) (
.

SCF .

Specific Heat

.
.

CV .

CP
.


.
pdv CP . CV
CP-CV=R .
CP CV .
Gas Entalpy
H .
)E ( )
( .
H=E+PV

.
.
)(PV

E+

=H

:
(PV)= 0
(P
T

E=CV

E+

=H

=)V

H=CVX T
:
)(PV)=P V=P(V2-V1
V

T+P

(PV)=CV

E+

T= (CP-CV) + T

=H
V=R

T=CP

T-CV

T+CP

H=CV

H=CP

Entropy
.

.

b

. ds = dQ / T
a

dQ .
.


.


CV

CP
, R = CP
CV

Avogadro Dalton


.

 :
MV = M 1V1 + M 2 V2 + M 3 V3 + ...
g1 g 2
g3
G
=
+
+
+ ...
M m1 m 2 m 3
CG = c1g 1 + c 2 g 2 + c 3 g 3 + ...

:
= M
= , m3 , m2 , m1
=G
= V
= ,V3 , V2 , V1
= C
= ,C3 , C2 , C1


) (
)(
.
.

 Boyle Law
Boyle
:
=PV

) (

.

Charles Law
Charles

:
P=C2T
C .
:
V=C3T

:
PV=nRT
P V T n )
W M n=W/M ( R
T,V,P,n .

.
) ( )
(


.


,
:
- Reversible Adiabatic Process
- Irrevesrsible Adiabatic Process
)(
.
.

pv = c = consant
Cp
Cv

Va
RTb
=)
Vb
Vb

( pb = pa

Pa 1 RTb
= ) ( Vb = Va
Pb
Pb
Va 1
Pb 1 Pb Vb
= ) ( Tb = Ta ( ) = Ta
Vb
Pa
R
.
W = PDV :

) P bVb Pa Va R (Tb Ta
=
1
1
RTa Tb
=W
(
)1
1 Ta
=W

Tb
Pb 1
) (=
Ta
Pa
RTa Pb 1
=W
) ([
]1
1 Pa

ABNM
.
PbVb BCON .
PbVb ADOM

) a b (
:
Pa Va

Pa Vb Pa Va
1

W = Pb Vb +

Pa Va )(1 +

W = (Pb Vb

) (P V Pa Va
=)
1 1 b b
Pb 1
]1] = C P Ta [( ) 1
Pa
1

Pb 1
)
Pa

([ RTa

=W

Pa Pb
. W .
WRTa Pb 1
= hp.ud.
*
) ([
]1
1
?
Pa

Ta
.



.
:
PV = C = CONSTANT
Va RT
Pb = Pa
=
Vb
Vb
Pa RT
=
Pb
Pb
Pb Va Pa Va
=
R
R

Vb = Vb

= Ta = Tb

:
Va
Va
= RTl
Vb
Vb

W = PDV = Pa Va l

Pb
Pa
= RTl
Pa
Pa

W = Pa Va l

W . ABCD
:
Pa Va

Va
Vb

W = Pb Vb + Pa Va l

Pa Va = Pb Vb
Va
Vb

W = Pa Va l

:
Va
Pa
= Rl
Vb
Pb

S = Rl

 :
Pb
Va
= RTl
Pa
Vb

H = RTl

Jacket
Cooling
) (

Utility

.
Ratio Of Comprssion
Ratio R
.
: .
R=(8+1)/1=9

.
, .

 The Heat Of Compression

.
. ,
.
.

.

) ( ) (
.


)
(. ..... .

.

CF

SCF

MSCF

MMSCF

)
(.
600MMSCF/D:
Horse Power
.
.
.
HEAD
Head

) (
Head .
Head Head
Head
.

 Head :
Pm Pa Va Pb ll 1
RTU Pb 1
P
= ]1
) ([
]1
) ([
= = P V m
=
1 Pa
1 Pa
dm
d1

=H

m
Head .
Head
:
-
-
-
) (
,
. psi .

.
) (.
Performance Curves
) (
.
.


.

.
:
Pi 1
) 1
nb 2
Po b
Hb
=
(
)
=
Pi 1
na
Ha

1
)
(
Po a
(

= (Pi)a ) (a
= (Po)a ) (a
= (Pi)b ) ( b
= (Po)b ) (b

Q/n
.
da db
db

da

b = a

:
db
da

Qb = Qa

Head
.


.
db
da

(B.hp) b = (B.hp) a

.
n = cons tan t

.


.

Pa/RTa
Ta :
db
pb
= Qa
da
pa

Qb = Qa

.
. Q n Q/n
Head
.

 :
Pb
Pa

(B.hp) b = (B.hp) a

,
) ( db=Pb/RTb Pb
:
db
Ta
= Qa
da
Pa

Qb = Qa

.
Head
Head :
)(B.hp)b=(B.hp)a (Ta/Tb
Q/n .

- Dynamic Compressors
- Positive Displacement Compressors
- Thermal Compressors
.

- Dynamic Compressor


.
:
- Axial Flow
- Radial Flow

- Axial Flow Compressor

) (

. .

Axial )
(

,
. )
( .

- Radial Flow
,
Vane
, Impeller
Impller Eye
Vane
VolouteDifuser

 .
) (
.

)
( Vane
. Volute

.


....... .
- Positive Displacement Compressors
) (
.

.


.
:
- Rotary Compressor
- Reciprocating Compressor
- )Rotary Compressor
) (
, ) (
) (
:
- Lobe Compressor
- Helical Lobe Compressors
- Sliding Vane Compressors
- Liquid Ring Compressors
- Lobe Compressor
Gas Suction
Lobe
Gas
Discharge .



Low Pressure
.
Lobe
Double Lobe Trial Lobe
. Lobe
.
.

- Helical Lobe Compressor

,
Screw Compressor
)( . Screw
) (

.

 Screw
Timing Gear
. Lobe
Lobe Cylinder


.
:
- Oil Free Compressor
- Oil Compressor
) (
) (

Separator

.
.

- Sliding Vane Compressor

Casing
Vane Suction


.
.
Vane


Vane Casing
.
Vane
.
.

 ,

.

- Liquid Ring Compressor

Egg Shaped
Cupped Blade . )
( .
Flare .

.
.
.

Casing
.

 Stationary Port Chamber

Stationary Port Chamber .


Casing
Separator
.

- Reciprocating Compressor




.


-
-
-



) (
.
Compressor Valves .

Cross Head .

- Single Acting
- Double Acting
Single Acting
Double Acting ) ( )
( 180
.
Shaking Force
.
.
-

) (

Comressor Valve .




.
.....
.

- .
-
.
-
.

 ) (
) ( .

) (
.
:
-
-


.
)
) St.St( ) (

)( Plunger
Pump

.

)( ) (
.

. Pressure
Switch

 .
.
Relief Valve
. Relief
ValvePressure Limiter

. . Relief Valve Needle
Valve Unload
Load .

 Compressor Valve
.
Channel Type .

.


Safety Valve Set
.
.

 :
- SingleStage
- Multistage

.
:
- .
- Inter Cooler .
- .
- Thermal Compressors
)
(

) (
.
Ejectors

.
.


.

Non Condense
. .
Steam )
( .
Vent
Vent


) (
.


-


)
(
.
-

.
-
.
-
)
( .
-)(
.
-
...
Safety Valve.
- )(
.... Snuber.
- ) (

.

 :
:
- .
- .
- .
- .
- .
- .
- .
.
.

 Dynamic Compressors


.


-
.
-
) ( .
-- )

(... .
- .

.
- .
-
.
:
- Cenrifugal Compressor
- Axial Flow Compressor
- Centrifugal Compressors

,

.
.

Centrifugal Compressor

) (
.

Impeller
) (Volute Casing ) ( .
) (Impeller Eye

)(


.


.
)(Head

.

.
,
.


:
- . Volute Casing Compressor
- Diffuser Compressor
- .
- Volute Casing Compressor


.
Discharge Nozzle .

. .
) ( ) 360
( )Nozzle

(Discharge

.
Radial Thrust




....... .



) (

.

- Diffuser Compressor
Diffuser .
)
( .
.
.

.


.
)
( .

 Multi Stage Compressor

.

. .

.

.

Impeller
.
Impeller :
- Enclosed
- Semiopen
- open
- Enclosed
Blade Shroud

. )
( ) (

)
(.
) Recirculation (
.

Labyrinth ) Wearing Ring
( .
.
- Semi Enclosed Impeller
:
-
-
-

.
.


.
- Open Impeller
Blade) (
.


Key .

.

Assymble
.
Centrifugal Compressor Construction

.
-


Pinion .
Bull Gear
.


) ( )
(

.
.

.
.


. Bull
)Gear (
.

 Low Speed Pinion

High Speed Pinion
)Bull Gear( )( )
( ) (
.


.
Batterfly Valve
)(
Inter Cooler
.


.
By Pass
) (....

Seat&Plug
.


.
.....

) .
Bull Gear
Pad
High &Low Speed

.

 High&Low Speed Pinion

Tilting Pad Self Align

. .
.

 ) (
Labyrinth .

.

HP
LP
Shroud Shroud

) (Shroud ) (
Shroud Shroud
) ( Shroud

Shroud .
Shroud .

 Shroud


)
( ) ( .
.. .



.
High&Low Speed Pinion

.
Casing :
- Horizontally Split Casing
- Vertically Split Casing

- Horizontally Split Casing

.
.
.

- Vertically Split Casing

Barell Type
.
:
Inner Case
- Outer Case

Cover
. Inner Case

 Outer Case ,
.

.

)
( .


)
(
.
Inner Case .

Inner Case


)(
.

 Inner Case
.


:
-
-
Radial Forces

). (

Single Volute Pumps

)
( ) (
Journal Bearing
.

 Diffuser .

.
.
.

.
.

- Thrust Forces

)
(


.
) (Thrust Bearing
.
.



.....
.

Balancing Piston
) (


) (H.P .

Drum
) Drum ( Drum .
Balancing Drum Head
Drum
. , Balancing Line
.

.

 Drum Drum Head Drum

.

:
- Drum )
( .
- Suction Pressure
) (.


. Drum
-
.
Balancing Drum
Drum



Balancing Drum
. Drum Drum Head
Drum

.
Cooling Systems
.
.
.

.

.

:
-
-
- Jacket Cooling




.
.


Inter Cooler Shell
Inter Cooler .

Shell&Tube
..

 Baffle

.

After
Cooler .
Jacket Cooling
.

.
.


Impeller



Casing .
)
(
.
Wearing Rings

) (Discharge )(Suction
. ) (
)
(


.

......

 .
Impeller Wearing Ring Casing Wearing Ring

.
.

)(
.

Diaphragm

:
-
- .
- .
- ) (.
.

Jacket Cooling

 .
.

Guide Vane
) (

. ) ( .
.
Adjustable Inlet Guide Vane
) (


( Capacity
.

 Unload
)(
.

Bateryfly Valve Controller
. Unload



Throtteling

 Bateryfly Valve
Surging .
Bateryfly Valve .

,


.
:
- .
-
.
.


)
(
:
- )(
.
- .
- )
(.
- .
- )
(.
- .
)(
, ,Float
, .......
.

:
- Carbon Rings .
- Lasyrinth Seal .
- .
- Dry Gas Seal .
.

 Carbon Seal Ring

.

Gater Spring
.
Stop Piece
)
(
.


.

 ) (
.

.

..... .


.


.. Drain

.

 Floating Packing Ring.

) (
,

) (

..... .


.

Carbon

Gland
) (

.
Horizontal Split




.
.



.
Labyrinth Seal


.
.

.

Eddy
) ( .

.
, , , .....
.
.



.
:

. .
.
- ) (
.
.

-

.

.

-
Inert Gas ,

Inert Gas

)( .

- Housing
Bearing .




.
-

.
Seal Oil

.



......... .

) (

.
Seal Oil
.
:
- )
( .
- .
- .
- .
Seal Ring

.



) ( .
Seal Ring
.
Seal Ring
:

)
( ) (
Intake Discharge

 ,
.


)
( ,
.


.

Sleeve


..

Sleeve .
Sleeve ) (
O-Ring
.

Iner SealOutre Seal )
( )
. ( Seal Oil Pump

B
) ( .


.

 )(
Inner&Outer Seal rings
. )(A
. ) (

) (
Outer Seal

Outer Seal )
(

.

C Seal Oil
C
Vent Back Pressure
.
F
)
( )
( Lube Oil
)(
Lube Oil
Lube Oil
Seal Oil .
) (F
.

 ) Seal Oil (
Buffer Gas
)psi (D D
Intake End)E, (Discharge End Labyrinth Gas Injection
,

A
. . A
.
, A
A
Traps Vent
Sour Oil Trap
.
Buffer Gas )
( D .
Buffer Gas A
Seal Refrence Pressure
Seal Oil B
Top Tank
Seal Oil

.
Loss
.

.

A
Sour Seal Oil

.

) (
) (
.
. Top Tank

) (
Seal Oil
Top Tank B .
A Refrence Gas

 Top Tank
) (
) (

.


) ( By Pass
Set Point
, )
( ,
.

Top Tank .

 Seal Oil Top Tank Seal

OilBuffer Gas Seal Oil

Seal Ring .

Float
) Self Align (

,

..
Buffer Gas
.
) (
Spectacle PlateGas Balance ) (
D
.
) (
)

 (
) (
.
Seal Oil System

.
) (
)
(
)
( .
Low Pressure
High Pressure

Suction
.Balance Line )

(



.


)
( Iner Seal Buffer Gas


)
( Outer Seal
.


Outer Seal
) ( )
(Vent Seal Oil Buffer
Gas ) (





Alarm&Shut Down
. .
:

 Seal Oil .

 Trouble Shooting
- Loss
-
-
- Buffer Gas
- .Top Tank

- Loss
-
- Buffer Gas
-

)
( .
-
-
- )( Reservoir
-
- Strainer
- )(
-
-
-
- Top Tank
- Seal Oil
-
- Out Put ) Out
Put .
- By Pass

 - ) (
Dry Gas Seal

) (


.

.
:
-

.
- )
,, (..............Top Tank
...........
-
-
.
-
Barrel
.
-
.
- Driver
- Seal Oil
........
-
-


.
Loss :
- *= .
- KW
** = .
.....



.

Seal Face

Dry Gas Seal
.
Dry Gas Seal Stationary
Float ) (
) Double Tandem
.

 Dry Gas Seal .

Groove
VU Directional Bi-Directional
) (
)
(
) (



.

.

 .

) (

.

 .

.

.

.
) (

.
Buffer Gas


)
(......... ) (

) (

)( .


)
( )
( .

Process Gas
Port 1



.
Port3 Port 2
) ( Flare .Port 3
Buffer Gas

Port 2
.
Port 5 )
Buffer Gas
.

.


Coalenscent
Filter
.
:

 Dry Gas Seals

On Line
Alarm Shut
Down .
:
- Process Gas P
) (0.2Bar .
- Port 2

Fail ) Port 2 (
.
- Process GasBuffer Gas

.

- )Buffer Gas Port 3 ( Port 2

)(0.2Bar .
-

-
)
, , , ,
Base ,Plate Surge ,
......... (


.


Process Gas Buffer Gas

.



.

Dry .

Clearance

.
)(
.


.

 :
- .
- .
- .
-
:
- Sleeve Bearings
- Roll Bearings


.
)( .
:
- Journal Bearing
.
- Thrust Bearing
.
Journal Bearings
.
.



) (

.
.
.
.
Oil Ring

 :
- .
- .
- .
- .
-
:
- Thin Shell Type
- Shell Bearing
.


-
,
, ......
, ...... .
- .
- .
- .
-
.
- Dampping ....

Oil Whirl .

 Oil Whirl

,
........



.

-
-
-
-
-

:

- Axial Groove
Damp.
- Lobed
.
- Titling Pad Titling
Self Aligning
Damping .
Axial GrooveLobed .

Titling Pad .

 Titling Pad Self Align

.
.

- Surge

........


.
.
)(

 .......
.
:
- Angular Cotact Ball Bearing
-
-
Angular Cotact Ball Bearing






,
.......


)(

) (

) ( .

.

.




.
) (





..... .
Thrust Pad Shoe .


.


:
- .
- ) (.
- ) (.
- .
-
.
- ) ( .
- .
- .
) Babbit (
.
.
.


. .


.

.

.


, , , ..... .

.
L
Sleeve
D

)L D

( .
L
1
D

L
. L
D

.
Sleeve Bearings

Forced Lubrication Oil Ring
) (


.

Clearance .
) (


) (


).
(.

 Bearing Clearance

:
-

.
- )
(
.
)
(
.
- Lead Wire


.
- Plastic Gage


.


.
-

.
Bearing Clearance


.



.
) (


Tab .

) ( Back
Press .

) ( )
( ) (Bearing Clamp




Crush .

 Bearing Crush
- Bearing Crush
Shell Bearing Lead Wire

.
,

Crush .

.




Back Press
.
- Bearing Crush
Thin Shell Type

 Rigid
) (


Bearing Crush

.

Bearing ClampBack PressBearing Crush

Bearing Tab
.
-
)(
) (

 , , .
..... .
Tilting Pad Inspection
Tilting Pad

Cage

.
.
:
.
: ) (


.

Thrust Pad


.
Axial Movement :
-

 -





.

Clearance :
:


:
:
: ) (
.
: .
: .

 Lubrication

:
-1
.
- .
- .
- .
- Carrier
.
- )
(.
- ) ( .
-
- .

.



.


.
.

:
-
.

- Viscosity
Viscosity Index
.
- ) (.
- .
-
.
- .
- ... .
-
.
- .
-
.... .
- ....... .
- .

, .






.
Adetive
.

) (
.


. Adetive
.
.
:
- .
- .
- ) ( .
- .
- Anti Oxidant.
- .Anti Foam .
- Anti Wear .
- .VI-Improver
- .
- ......


.
:
-
-
-
- .......



Oil Ring


.

.
Oil RingSlinger Ring

.




) (
.


.
Oil Pot
Levling Rod.

.

.
. Adjusting
) Nut (

.

.
`Oil Pot
.

 Oil Pot ) (
.

:
: Oil Pot
.
: Oil Pot
Oil Pot
.

 :


.

Oil Ring
Oil Ring .

Forced Lubrication



.

 Oil Reservoir

.
:
- .
- .
- .
- Safety Valve .
- ......
.
- ...
- Alarm Shut
Down :
- .
- .
- .
-

Bleader
.
- .
- .
- .

-- , ,
.
.

)
(
.


- .Flush
- Set Point
.
- .
-
Shut Down , Alarm .
-

.
-
.
- Setting Safety Valve
.

- ) (.
Stand By Pump Running- Failure Main Oil Pump



Setting

.
- Filter High Differential Pressure

Tapping D.P ,
.
- Shut Down
.......
- ) (
.
- .
- .Cooling Water

, Top Tank
D.C .
D.C


,) (

)
( Trip

. UPS
.

Lube Oil Accumulator

Blader
.

Trip
.

Seiz .

Lube Oil
.
Top Tank

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Alignment

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On Line Condition Monitoring

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Energize .



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Washer...
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Shut Down Alarm
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Female Rotor
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Seal
.

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Air Filter

Intake

Silencer Battery Fly Valve

Intercooler
HP

Silencer

Outlet

Valve

Check

Aftercooler .
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Single Stage
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Unloal :
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.
Unloading Valve
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Bleed-Off Cooler
Circulation



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LP
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Gear Drive Gear
Gear Pump ......
Gear Casing
Drive Shaft Gear Casing

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Bypass Valve
Sump
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Low Oil
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Cooling Water System
Cooling Water
:
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120mg/lit .
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After Cooler Moisture Trap
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Unloader Valve.
:
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Air Pressure Switch

-
.

Load&Unload
Inlet Valve Setting

Unloading

 Unloaded Operation

Unloading Pressure
Air Pressure SwitchDe-energized Y1

Shuttle Valve
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( Unloading Valve Unloading Valve
Bleed-Off Cooler
Check
Valve .
Unload .

 Unloader Piston
Switching Valve) (
.
Loading Pressure
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Toggle Switch Unload.

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Energized 10
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.
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LP Unloader Piston
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Unloader Piston (.
TV Unloader Valve
Check Valve .
Unloading Valve )(
Control&Fault Indicator


:
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Over Load- .
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-

 Compression Starting
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.

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- .Unloader Cylinder
- .
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- .
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Unloader Cylinder
Bar
UnLoader Cylinder
. Unloader Piston
Rolling Diaphragm
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... Seat&PlugUnloading Valve .
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- Air Pressure Switch
.
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- .
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-
- Time Relay .
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) (.
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- .
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- .
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-
-
- .
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-
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- .
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- .
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.

- .
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Setting- .
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Surge
.
.:
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- Blow off . Plant
.
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Setting :
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- 4pi % .
- 1sv 2sv Energize
1vc 2vc Plant
.
Surge
1sv Energize .

 Intermitent Control
3ss .
Blow Off
Off
On .

Blow Off ) ( 1sv ) ( 2sv
. Signal ) ( 1sv , 2sv
) (3 Vent .
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0
Control Panel . Setting
*
. :
Proportional Band -
Rest Rate Responses -
Lc Pc Sc Plant
.
%
Proportional Band
0.05 Minutes / Repeat .


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.
) ( 3PR Surge .
Surge
.
: .
LC Load .
Load .
Electrical Control System
.
Tripping .

3ss . 3ps . 4ps . 3CR

3ss
ON . ) ( 4ps 35 Deenergize . )
( 13cr load 35 3ps 35
bcr 35 Load
) ( Blow Off

 Annunciator
Shut Down

Alarm Group

1-1

1-2

1PS ) ( Ecr
) 6cr .
) ( 1TAS .

2-1

) ( 2TAS .

2-2

) ( 3TAS .

3-1

) ( 4TAS .

3-2

V M - AR

N.O ) ( Customer
Vibration Monitor

 Thrust Bearing Vibration Monitor

. Set Point
) ( VM AM Signal ) Point ( 3 2
.
Set Point

Shut down ) ( VM DR

De-energize ) 12 ( CR ) ( Point 3 s
Trip .