Yasir Arafin

Junior Engineer in Operations

Karnaphuli Power LTD, Patia, Chittagong

What is Screw compressor?

A rotary screw air compressor is a type of positive displacement air compressor that uses two
intermeshing screws (or rotors) to compress air. The male and female rotors rotate in opposite directions,
drawing in air at one end and forcing it out the other at a higher pressure.

Figure : Male and Female Screw of a compressor

Positive displacement compressors

Positive displacement compressors trap a volume of air in a space and then decrease the volume of that
space. Examples include reciprocating, screw, rotary slide or vane and scroll compressors.

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 Yasir Arafin
Junior Engineer in Operations
Karnaphuli Power LTD, Patia, Chittagong

Principle of Screw compressor

Intake: Air enters the compressor through an inlet filter, removing dust and debris to prevent internal
component damage.

Compression: The heart of the compressor lies in the intermeshing male and female rotors. As these
rotors rotate, air gets trapped between their lobes and gradually compressed as the volume between them
decreases.

Separation (Oil-injected compressors only): After compression, the air-oil mixture passes through an
oil separator where the oil is separated from the compressed air.

Aftercooler or Air dryer: The compressed air then flows through an aftercooler which removes moisture
condensation through heat exchange, preventing corrosion and ensuring clean, dry air output.

Discharge: Finally, the compressed air is delivered to the application through a discharge line and
receiver tank (for storage).

Types of Screw Air Compressors

Screw air compressors come in various configurations to cater to specific application requirements. Here
are the two main types:

Oil-injected screw compressors: These are the most common type, offering high efficiency, reliability,
and durability. The injected oil cools and lubricates the internal components, extending their lifespan.
However, oil separation is necessary to ensure clean and dry air output.

Oil-free screw compressors: As the name suggests, these compressors operate entirely without oil,
resulting in completely oil-free compressed air. This is crucial for applications requiring contamination-
free air, such as in food and beverage production, electronics manufacturing, and medical facilities.
However, oil-free compressors generally have higher initial costs and require stricter maintenance.

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 Yasir Arafin
Junior Engineer in Operations
Karnaphuli Power LTD, Patia, Chittagong

Applications: Where Shine?

Screw air compressors find application in a wide range of industries due to their reliability, efficiency, and
ability to deliver continuous high-pressure air:

Energy generation: Pneumatic tools for control valves, Automatic PID controller, Engine instrument air.
Manufacturing: Powering pneumatic tools for assembly lines, sandblasting equipment, and paint
finishing applications.
Construction: Operating jackhammers, drills, and other construction tools.
Automotive: Supplying air for tire inflation, spray painting, and bodywork tools.
Food and beverage production: Providing clean, dry air for packaging, bottling, and other processes.
Oil and gas: Used in various stages of oil and gas exploration.

Advantages of Screw Compressors

 No Pulsation: With a smooth rotating motion, a screw compressor produces a continual flow of
air with no pulsing. Compressed air often pulses when created via piston compression.
 Continuous Operation: Screw compressors are ideal for situations that require continuous
operation rather than intermittent use.
 Control Output: Because of the smooth flow rate, screw compressors offer simple and fluid
control of air volume, making it one of the most precise designs in air compressor history.
 Low Vibration: The rotational nature of the screw means that vibrations are minimal, making it
an excellent solution for sensitive environments where vibrations can interfere with equipment.
 No Abrasion: Unlike piston compressors, screw compressors have little wear and tear because of
the continual, smooth rotation of the central screw shaft. This results in few repairs and even fewer
replacements being needed.

Disadvantages of Screw Compressors

Although screw compressors are brilliant for some applications (which we will discuss below), they do
have some disadvantages. These include:

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 Yasir Arafin
Junior Engineer in Operations
Karnaphuli Power LTD, Patia, Chittagong

 Cost: Due to their more advanced design, screw compressors often cost more than their piston
counterparts.
 Intermittent Loads: The rotating, continual motion of a screw compressor is perfect for continual
use, but it is not ideal for intermittent loads. Stopping and starting a screw compressor regularly
can cause issues in some circumstances.
 Maintenance: Although maintenance is less frequent for a screw compressor, it can also be more
complicated. If something does need repaired, this can often result in the need for reassembly and
alignment of the screw shaft. Screw compressors require precision performance, and so qualified
technicians are preferential for such maintenance work.

Key parameters to monitor

 Discharge pressure
 Internal temperature
 Inlet pressure
 Differential pressure across air filters
 Aftercooler outlet temperature
 Oil level and temperature
 Operating hours

Importance of air intake filtration in a rotary screw compressor for

instrument air
Air intake filtration is crucial to remove dust, dirt, and other contaminants that can damage the
compressor and degrade instrument air quality.

Different types of filters

Common filter types include:
 Dry media filters: These remove dust and particulate matter.
 Coalescing filters: These remove water droplets and aerosols.
 Activated carbon filters: These remove odors and some gaseous contaminants

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 Yasir Arafin
Junior Engineer in Operations
Karnaphuli Power LTD, Patia, Chittagong

Aftercooler in a screw compressor for instrument air

The aftercooler removes moisture from the compressed air by cooling it down below the dew point
temperature. A well-designed aftercooler with sufficient cooling capacity ensures efficient moisture
removal for clean and dry instrument air.

What is Dew point ?

The temperature at which moisture in the air will begin to condense. At this point the relative humidity is
100%. Dew point is often used in pneumatics to represent the amount of moisture in a compressed air
system

Concept of Pressure Dew Point (PDP)

Pressure dew point (PDP) is the temperature at which water vapor in compressed air condenses into liquid
water at a specific pressure. Maintaining a PDP lower than the minimum instrument operating
temperature prevents condensation and ensures clean, dry air for instrument operation. More information
on Pressure Dew Point can be found from compressed air treatment equipment manufacturers.

What Is FAD ?
Free air delivery (FAD) is the actual quantity of compressed air converted back to the inlet conditions of
the compressor. The units for FAD are generally measured according to the ambient inlet standard
conditions Ambient temperature =20ºC, Ambient pressure =1 bar abs, Relative humidity =0%, Cooling
water/air =20ºC and Effective working pressure at discharge valve =7 bar abs. CFM - Cubic feet per
minute – Also known as cfm or scfm (standard cfm), a measurement of the flow of compressed air.
.

Different types of dryer

There are four main types of dryer:

 Refrigerant dryers
 Desiccant Dryers

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 Yasir Arafin
Junior Engineer in Operations
Karnaphuli Power LTD, Patia, Chittagong

 Deliquescent
 Membrane

Gardner Denver GDD-100S is a Refrigerant dryers

Find Alarms in Gardner Denver Compressor

Dryer selection
The type of dryer selected depends on the application and in turn;
 The dew point required.
 The pressure.
 The inlet temperature.

Operation and Maintenance checklist

Compressor

 Intake filter appropriate periodic clean or replacement

 Oil filters appropriate periodic clean or replacement
 Compressor oil periodic replacement
 Injected oil periodic replacement
 Interim and full service as per manufacturers schedule essential
 Drive maintenance – Belts, motors, bearings Inter cooler heat exchange surfaces clean

Treatment

 After cooler inspection and operation check pre dryer temperature

 Maintain critical pre dryer filtration and water separation
 Dryer performance check
 Receiver condition and drainage Post dryer temperature
 Regularly replace post dryer filtration

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 Yasir Arafin
Junior Engineer in Operations
Karnaphuli Power LTD, Patia, Chittagong

Compressed air Distribution

 Evaluate pressure and monitor system pressure drop

 Check the correct operation of traps and separators
 Change cartridge filters regularly

Leakage

 Check and monitor system pressure drop over time

 Conduct audible surveys on a regular basis
 Generate at lowest pressure for majority use
 Minimize flexible hose lengths
 Check and or replace quick couple