Optimum COnfiguratiOn fOr Oil-injeCted

SCrew COmpreSSOrS
Twin-Screw, Oil-Injected Screw Compressors Have Higher Compression Ratios,
Simplified Design, Efficient Operation and Greater Reliability Than Oil-Free Designs
By Amin Almasi

Screw compressors have many inherent advantages over The focus here is on the oil-injected type. The operating
other compressor types (mainly reciprocating and centrifu- principle of screw compressors has been known for over
gal) in the low- to medium-flow range. Since they are posi- 125 years. Despite serous efforts to produce them, they
tive displacement compressors, they will draw a constant were not made until low-cost manufacturing methods be-
inlet volume, can meet the varying differential pressure re- came available for accurate machining of the rotor profile
quirements and are not significantly affected by gas density (precision cutting and machining tools). Since then, great
or composition. improvements have been made in performance prediction,
Compared to reciprocating compressors, pulsations rotor profile and manufacturing techniques. They have
are considerably reduced, suction and discharge valves largely replaced reciprocating compressors and centrifugal
and troublesome unloaders as well as high maintenance compressors for many industrial and process applications.
packing are not required. Rotary motion significantly re- Fig. 1 shows screw compressor components including ro-
duces the footprint of the screw compressor unit com- tors and casing.
pared to other positive displacement alternatives. The
result is an efficient, reliable, simple and compact com-
pressor that is very competitive from an initial cost and
installed cost standpoint.
Two types of twin screw compressors are available, oil
free and oil injected (oil flooded). Although both types
use helical rotors (screws), many significant differences
can be identified between the two types. Oil-injected
screw compressors are the newest type. Compared to dry
type, oil-injected screw compressors enable much higher
compression ratios, simplified mechanical design (such as
eliminating the timing gears), more efficient operation and
greater reliability.

Amin Almasi is lead rotating equipment engineer in Worley

Parsons Services Pty Ltd., Brisbane, Australia. He previously
worked in Technicas Reunidas (Madrid, Spain) and Fluor (vari-
ous offices). He holds a chartered professional engineer license
from Engineers Australia (MIEAust CPEng Mechanical),
chartered engineer certificate from IMechE (CEng MIMechE),
RPEQ (Registered Professional Engineer in Queensland) and
he also holds BS and MS degrees in mechanical engineering.
He specializes in rotating machines including centrifugal,
screw and reciprocating compressors, gas and steam turbines,
pumps, condition monitoring and reliability. Almasi is an active
member of Engineers Australia, IMechE, ASME, CMVI, Vibration
Institute, SPE, IEEE, SMRP and IDGTE. He has authored more
than 40 papers and articles dealing with rotating machines.
For additional information or answers to questions, contact the
author via his e-mail addresses: amin_almassi@yahoo.com or
amin.almasi@worleyparsons.com
Figure 1. Screw compressor components including rotors and casing.
The technical and cost advantages of oil-injected screw
compressors have made them the compressor of choice
for many small- and medium-capacity applications. They
are employed to compress gases for various process appli-
cations (ethylene, acetylene, etc.), gas processing, natural
gas systems, flare and recovery gas applications, air sys-
tems, various refrigeration systems, biomass gas systems,
coke oven and coal gas systems, hydrogen, nitrogen and
many more.
Compressor Design and Selection
The description oil-injected implies that lubricating oil

December 2010 62 CompressorTechTwo

or a suitable synthetic lubricant (or alternative liquid) is Continuing to Lead The Industry
deliberately injected into the gas compression space and is with 286,000 SF of Manufacturing
allowed to mix freely with the process gas. There are five Facilities on 38 Acres
important benefits to be derived from the injection of oil
into the compressor:
1. Oil acts as a coolant, thus enabling the discharge tem-
perature to be closely controlled. Differential expansion
caused by thermal growth can result in reduction of running
clearances in screw compressors, leading to interference be-
tween casing and rotors. By injecting a calculated flow of
oil, the discharge temperature is controlled, usually in the
range of 176 to 212F (80 to 100C). This feature permits
relatively large pressure rises across the compressor and ob-
viates the need for jacket or rotor cooling.
2. For optimum efficiency, internal clearances within the
compressor must be kept as small as possible. However,
because of the presence of large quantities of oil within the
machine, there is no danger of contact between the rotors
and the casing. The oil also serves as a sealant, partially
filling the clearance between rotors, rotor-and-casing and
the blowhole.
3. The injected oil acts as a lubricant, enabling the main
rotor (usually the male) to drive the other rotor through a
film of oil. Thus, an oil-injected screw compressor does not
require a timing gear between the rotors to ensure that there
is no metal-to-metal contact. This results in a simpler and
less expensive compressor. The lubricant effect also permits
the use of a slide valve capacity control system, capable of
controlling volume flow between 10 to 100%, providing the
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SOLVED
ing conventional carbon steel or grey cast iron as materials
of construction.
BOLTING
PROBLEMS
5. Oil acts as a noise damper. Combined with low rotor
lobe passing frequencies, this has the advantage that most
installations do not require extensive sound attenuation to
meet acceptable site noise levels.
Generally, grey cast iron may be suitable for pressures up
to 217 psi (15 bar). Steel and spheroidal graphite (SG) iron
casings can handle pressures up to 580 to 725 psig (40 to 50
bar). Refer to API 619 for material selection. Discharge pres-
sure of screw compressors is limited by various factors: 1.
Gas discharge temperature, 2. Rotor length-to-diameter ratio
(L/D ratio) and 3. Material and casing design.

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compression stroke commences. The volume trapped in
the flutes is reduced until the outlet port is uncovered and
the compressed gas is discharged. There is no re-expan-
sion, as there is no gas trapped in a clearance volume. Vol-
ume ratio is an inherent physical feature of a given screw
compressor design. Fig. 2 shows a working mechanism of
a twin screw compressor.
Rotor speeds are such that dynamic balancing is required
for proper vibration control. While the critical speeds are
generally above the operating speed, review of the rotor
dynamic is required. Forged carbon steel rotors for all non-
corrosive applications and high alloy steel (such as 13%
Cr, 4% Ni) for corrosive applications are in common use.
Nearly all stainless steels are prone to galling, which is par-
ticularly likely with screw compressors that have very fine
operating clearances.
Various screw profiles are available. Their use depends on
the process conditions, flow and pressure conditions, and
type of screw compressor. The most common profile is the
asymmetric 4+6 (4 lobe male and 6 flute female). For spe-
cial rotor applications, rotor experience reference is required
during bidding phase. Figure 3 illustrates a 4+6 asymmetric
profile A predominantly used for medium and large oil-
injected screw compressors, a common profile. Figure 4 il-
lustrates 4+6 asymmetric profile D predominantly used for
a small oil-injected screw compressor.
Figure 3. Illustration of
4+6 asymmetric profile
A predominantly used
for a large oil-injected
screw compressor.
Figure 4. Illustration of
4+6 asymmetric profile
D predominantly used
for a small oil-injected
screw compressors.
Some vendors furnished coatings for the rotors in order
to keep the rotor from wearing and losing seal clearance.
One such coating is TFE. There is a vast diversity of opinion
on the value of coatings in light of varying performances.
It is not recommended except for the purpose of renewing
clearances at the time of maintenance. For this case, some
vendors usually use a renewable seal strip.
Differential pressure across any stage shall not exceed the
maximum allowable values depending on rotor design. This
limit can vary from as much as 435 psi (30 bar) for L/D=1.1
to as low as 116 psi (8 bar) for L/D=2.2 (for conventional 4+6
profile combination). The reason for this limitation is rotor
deflection. The larger the L/D value, the greater the bearing
span and larger the rotor deflection. The use of higher rigid-
ity rotors with, for instance, a 6+8 profile combination and
L/D=1, can provide a differential pressure capability of as
much as 725 psi (50 bar).
Male and female rotors of a screw compressor theoreti-
December 2010
cally contact each other on a sealing line. There is a clear-
ance distribution along this sealing line between rotors.
As this clearance influences the compressors efficiency
and reliability, controlling the clearances is important. The
amount of clearance depends on profile error, thermal de-
formation, center displacement and relative rotational angle
between rotors.
Medium and large screw compressors incorporate sleeve
bearings (also called journal bearings or sliding bearings) and
self-adjusting multisegment thrust bearings. Small machines
are often equipped with hardened steel, rolling-element
bearings that have very little tolerance for water and cor-
rosive agents (such as H2S). The majority of compressors for
process gas applications are furnished with sleeve bearings.
The service life of sleeve bearings is particularly unlimited as
long as proper lubricating and operating procedures are in
force. These bearings are also far more tolerant of water and
corrosive agents compared to steel rolling-element bearings.
Sleeve (plain) bearings with white metal-lined shells are in
common use. The choice of tin or lead-rich alloys is influ-
enced by the gas handled.
For difficult services, unusual bearings may be used, such
as graphite with a sulfuric acid-injected medium. Because
the highest loads in a screw compressor are axial, the thrust
bearing is the component most susceptible to premature fail-
ure. The compressor should, therefore, be protected by em-
bedded temperature sensors mounted in the thrust bearing
pads of the axial bearings. API 619 requires the bearings to
be removable without removing the rotors or the upper half
on the horizontally split machine.
Oil-injected screw compressors require only one seal
where the driver shaft enters the casing. Generally, the driver
is a direct-coupled electric motor. Optimum coupling selec-
tion is one with high torsional stiffness (metallic flexible cou-
pling as per API 671).
Process and Performance
Accurately defining gas contamination and percent per
unit volume is most important. For example, sour gas or
corrosive agents must be accurately defined and will de-
termine material and oil types, etc. An important feature
of a screw compressor is its ability to achieve the required
outlet pressure regardless of the molecular weight or gas
composition. The compressor process that starts on ni-
trogen and then gradually picks up hydrogen-rich gas
mixture does not change in performance (it is a great ad-
vantage compared to dynamic compressors such as cen-
trifugal compressors).
The screw compressor module has to be fully integrated
into the process system. Special care must be taken to ensure
that the compressor receives gas at the designated condi-
tions. If particulate contamination of the gas, solid or liquid
exists in large quantity, erosion and lubrication problems
may result. In these cases it is necessary to install a required
knock-out drum, separator and filter upstream of the com-
pressor inlet.
Information on the effectiveness of upstream separation
and filtration systems can be of extreme importance. To
ensure high-reliability, low-maintenance installations, these
data must be supplied by a competent and knowledgeable
vendor and confirmed by a third party. In many instances,
the root causes of machine distress are centered on the up-
stream separation equipment. Minimum filtration require-
ment for oil-injected screw compressors is inlet filters with a
200 micron mesh.
Capacity Control
Oil-injected screw compressors are usually fitted with a
slide valve that permits the suction volume to be reduced.
64 CompressorTechTwo
 CALL ON EXLINE
This step-less control of capacity, while maintaining high ef-
ficiency, is one of the main advantages of oil-injected com-
pressors. These compressors are generally constant-speed
machines. Suction throttle capacity control may be used only
for small screw compressors. It is not efficient and may also
cause some operational and reliability problems regarding FOR ALL YOUR
discharge temperature and differential pressures.
A variation of the slide valve is the turn valve. The valve MAINTENANCE NEEDS
functions by turning rather than sliding but has the same ef-
fect as the slide valve. The plug is grooved and the compres- From major equipment
sor casing is slotted. As the valve turns, the grooves move overhauls to minor
away from the slots, passing a quantity of gas. The leakage inspections, the Exline
in this valve is greater because of the imperfect matching of Field Services Division
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Lube Oil and Auxiliaries and service to keep
Oil must be compatible with the gas, and occasionally
your machines rolling.
very small carryover of the lubricant can be tolerated. The
maximum temperatures that gases are allowed to reach in an We specialize in reciprocating
oil-injected screw compressor are usually determined by the engines, compressors, generators,
lubricant. For mineral oils, the normal permitted maximum rotating equipment, and other industrial
is in the range 194 to 212F (90 to 100C). Some synthetic equipment.
lubricants will permit this discharge temperature to be re-
laxed up to 266F (130C). For above 212F (100C), the de- Your Single-Source
sign of the compressor must be checked carefully to ascer-
tain the effect of thermal growth on the internal clearance
Field Services Solution
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ate at higher temperatures and are being used increasingly. see directlink At www.compressortech2.com
In the absence of reactive gases (oxygen, etc.) mineral oils
can operate at much higher temperatures though their vis-
cosity drops rapidly with rising temperature. Some synthetic
lubricants, with high viscosity indices, can be used over a Improve Performance,
Restore Efficiency
large temperature range. Factors to consider when selecting
the lubricant include: 1. Oxidation, 2. Condensation, 3. Vis-
cosity, 4. Out-gasing in the inlet, 5. Foaming, 6. Separation
performance, and 7. Chemical reaction.
Some of the problems can be solved with specially se-
lected oil grades. Cost is a problem with synthetic oils, par-
ticularly with silicon oils. Alternatives must be reviewed to
match service life of the lubricant with lubrication require-
ments. For chemical service, some lubricant qualities may
be sacrificed in order to obtain a fluid compatible with
the process gas. In these applications, alternative bearing Count on Foley Rebuild Centers trained technicians and
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some special applications. 2010 Caterpillar All rights reserved. CAT, CATERPILLAR, their respective logos, Caterpillar Yellow,
continued on page 66 the Power Edge trade dress as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.

December 2010 65 see directlink At www.compressortech2.com

FoleyEq-161.indd 1 11/15/10 3:53 PM

 Oil-injected screw compressors will employ a pressurized
lubrication system. All of these compressors will require an
oil separation system that is usually combined with the lubri-
cation system. Experience has shown that bearing and seal
component reliability is a direct function of auxiliary system
component selection and design. Auxiliary systems are ma-
jor sources of potential cost reduction for screw compressor
vendors (to compete and win). Since screw compressors are
relatively new, the specifications may not reach the required
sophistication in some specific areas.
A strong recommendation is that all auxiliary systems (es-
pecially oil systems) be thoroughly reviewed in the bidding
stage. Special care should be given to oil selection, separa-
tor retention time, oil pumps, coolers, oil filters and vendor
experience for similar applications. The oil recovery vessel,
known as the primary separator, is generally equipped with
suitable internals and wire mesh demister devices (or alter-
native devices) to remove the oil from the gas following
compression down to a residual oil carryover of 50 to 100
ppmv. In medium and large process compressors, the vessel
is usually arranged vertically, provided with man-way ac-
cess and mounted on the compressor unit base frame. The
vessel is normally fabricated in carbon steel. The demister
pack is usually constructed of stainless steel. The lower part
of the vessel serves as the reservoir for the oil management
system and can usually be designed with an oil retention
time of 60 to 90 seconds (API recommends a minimum of
120 seconds). When particularly corrosive gases are being
compressed, lining the upper part of the vessel (i.e., above
the demister pack) with an epoxy or glass-based substance
is usual practice.
Special care is needed for oil pump selection and siz-
ing. Oil pump operating discharge pressure is selected
based on compressor discharge pressure plus a margin
(usually 44 psi [3 bar]), to ensure proper oil injection.
Ample margin (25 to 30%) is needed for rated flow (com-
pared to normal oil flow). Recommendation for oil pump:
Two identical motor-driven oil pumps according to API
676. Other oil system components: Two 100% lube oil
filters (filter body and internal: stainless steel), twin lube
oil shell and tube-type cooler according to TEMA C (or
alternatively air cooler API 661 with spare fan, if cooling
water is not available).
An oil purifier or oil conditioner is either a portable or
installed device that can be used to decontaminate or purify
a circulating oil stream that has been slowly degraded by an
influx of contaminations. Such a device will not normally
require shutdown of the compressor. Since the finite volume
of oil used in oil-injected machines will slowly but surely
become contaminated by any particulate matter or water that
finds its way into the compressor space, such a device is
usually required for reliable operation. The need for purifica-
tion is also a function of the effectiveness of the compressor
suction scrubber and frequency of changing the elements in
the oil filter.
Compressor Applications
Although originally intended for air compression, oil-
injected screw compressors are, in the 21st century, com-
pressing a large number of process gases in the oil and gas
plants, refineries, petrochemical units, air separation plants,
refrigeration units, various cryogenic plants, LNG/LPG units,
evaporation plants, mining and metallurgical plants.
Many upstream applications use gas turbines as prime
movers for power generation and large pump and compres-
sor drives. Oil-injected screw is rapidly becoming the com-
pressor of choice in gas turbine fuel gas booster applica-
tions, which require medium flow, pressure ratios and the
ability to handle varying gas densities and conditions. As the
December 2010
characteristics and advantages of screw compressors become
more widely appreciated, their use in all types of applica-
tions will increase. Practically all gases can be compressed.
Some manufacturers have dozens of oil-injected twin screw
compressors in successful service for at least three years of
uninterrupted service for various applications. Many cases
are documented of screw compressors staying online for six
or more years. Uninterrupted service is the key here, with a
particular gas composition.
Special modifications and considerations may be required
for use of oil-injected screws in specific gas services (such
as sour gas services). The standard design of a discharge oil
separator downstream of the machine (i.e., standard 60- to
120-second retention time) do not allow specific gas com-
ponents (such as sour gas) to be vented from the oil reser-
voir. This can lead to oil contamination, screw component
damage and frequent oil change. Vendors experience lists
should be required and checked, and suitable reservoir ca-
pacity identified. This should be done in the bidding stage
before package order.
In process applications, oil-injected screw compressors
are ideally suited for compression of gases that tend to po-
lymerize at relatively low temperatures. For special applica-
tions, a suitable liquid (instead of oil) may be injected into
the compressor. Modern two-stage screw compressors with
water injection are being used in several coke gas produc-
tion plants. Other types of compressors (such as centrifugal
compressors) are highly vulnerable to performance degrada-
tion because of rapid polymerization of this relatively dirty,
hydrogen-rich gas (in some cases centrifugal compressors
experience costly downtime every six to eight weeks for in-
ternal cleaning).
Condition Monitoring and Reliability
The keys to reliability and maintainability are modern seal
and bearing design, and proper arrangement and modular-
ization that enhances efficient maintenance. Optimum con-
dition monitoring of screw compressors effectively moni-
tor: Rotor (performance including flow trend and efficiency
trend), journal and thrust bearing (mainly bearing tempera-
ture and casing vibration monitoring), seal and oil system.
A trend of delivered flow is useful because screw compres-
sors are positive displacement compressors and will deliver
a constant volume.
Reduction of flow is an indication of an increase of slip
(internal leakage). Care must be taken in trending flow, how-
ever. Rotor speed, suction throttle valve (if used), slide valve
and bypass position can also affect flow. Trending adiabatic
efficiency is another useful indicator of performance. Again,
care must be taken to ensure oil injection, cooling effects,
slide and bypass valve positions are constant.
Off-design operation should be avoided for long-term
reliability. For example, if the compressor is run around
86F (30C) more than rated discharge temperature, loss
in area would result in an efficiency loss more than 1%.
In the long term, it can cause more deterioration and reli-
ability issues.
Commercial Conditions and Vendor Data
Screw compressors have many advantages over other
types and can usually be purchased for a lower cost in the
small and medium range. Currently, there are many com-
petent and capable vendors for oil-injected screw compres-
sors and it is not difficult to select a low-cost, technically
accepted and reliable oil-injected machine. Compared to
dry-type screw compressors, it has great advantages be-
cause for large dry-type screw compressors for specific ap-
plications, there are only two capable vendors (users have
only two options).
66 CompressorTechTwo
 All duties should be specified in full in documents. IDEAL ANALYZER TO MEASURE
Compressor manufacturers should be permitted freedom
to optimize the machine configuration. However, vendor
ENGINE EMISSIONS
guarantee has a very limited time compared to machine
life and long-term reliability, and compatibility with proc- E Instruments provides the latest technology in hand-
ess and plant needs to be carefully checked by purchaser held instrumentation with the New E4400 analyzer
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eters are mandatory and which are desirable. Limiting val-
ues should be given as necessary. The data sheet should
tests as well as tuning and maintenance of rich and lean
include all of the identifiable process duties. One duty burning gas & diesel engines.
should be designed rated point, which defines the ex-
tremes necessary to meet all specified operating points. It
will dictate the size of the compressor. This may be the E4400 features include:
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Field Replaceable &
Conclusion Pre-Calibrated Sensors
In various small- and medium-sized applications in dif-
Internal Non-Thermal
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see directlink At www.compressortech2.com
References
Bloch, H. P., A Practical Guide to Compressor Technology,
2nd edition, 2006 (John Wiley, New Jersey, U.S.A.). Einstruments2.indd 1 7/30/10 8:57:08 AM
Bloch, H. P., Compressor and Modern Process Application,
2006 (John Wiley, New Jersey, U.S.A.).
Davidson, J.; Bertele, O., Process Fan and Compressor
Selection, pp. 112-145, 1996 (Mechanical Engineering Publi-
cations Ltd., London, England).
Kovacevic, A.; Stosic, N.; Smith, I., Screw Compressors,
2007 (Springer-Verlag, Berlin, Germany).
Brown, R. N., Compressors Selection and Sizing, Third
Edition, pp. 120-220, 2005 (Gulf Publishing Co., Houston,
Texas, U.S.A.).
Bloch, H. P.; Soares, C., Process Plant Machinery, Second
Edition, 1998 (Butterworth Heinemann, Oxford, U.K.).
Forsthoffer, W. E., Forsthoffers Rotating Equipment Hand-
books Volume 3: Compressor, First Edition, 2005 (Elsevier,
Oxford, U.K.).
API 619, Rotary-type Positive Displacement Compressor
for Petroleum, Petrochemical and Natural Gas Industries,
Fourth Edition, December 2004 (American Petroleum Insti-
tute Publishing, Washington, D.C., U.S.A.).
Kameya, H.; Takeda, F.; Aoki, M.; Inoue, K., Simpli-
fied Method for Calculating Inter-lobe Clearance Distri-
bution along a Sealing Line between Rotors of a Screw
Compressor, pp. 193-202, International Conference on
Compressors and Their Systems, City University, London,
England, Sept. 10 to 12, 2007 (Chandos Publishing, Ox-
ford, U.K.).
Mujic, E.; Kovacevic, A.; Stosic, N.; Smith, I., The Influ-
ence of Port Shape on Gas Pulsation in a Screw Compressor
Discharge Chamber, pp. 213-222, International Conference
on Compressors and Their Systems, City University, Lon-
don, England, Sept. 10 to 12, 2007 (Chandos Publishing,
Oxford, U.K.).

December 2010 67 see directlink At www.compressortech2.com