Professional Documents
Culture Documents
As the rotors turn, gas is drawn through the inlet port to fill the space between adjacent lobes.
When the interlobe space along the rotor length is filled, the rotation of the rotors moves the end
of the lobes past the inlet port sealing the interlobe space.
As the rotors continue to rotate, the intermeshing of the lobes on the discharge side of the
compressor progressively reduces the space occupied by the gas, causing compression.
Compression continues until the interlobe space becomes exposed to the outlet port in the casing
and gas is discharged.
Lubricating oil is injected into the compression chamber in most applications to absorb most of
the heat of compression and to seal the running clearances between the rotors, enabling the
machine to operate at high pressure ratios in a single stage.
Table 2. Possible causes for repeated seal failures.
Mark 1 = The generation or release number. The 163-mm compressor is still in its first
generation having been introduced in 1973. The 204 mm compressor in its sixth generation.
WRV = (W) Wet, oil injected; (R) refrigeration; (V) volume, capacity control.
XXX = The digits following the vi are the discrete serial number for that configuration
compressor.
The correct and complete identification of a compressor is vital in obtaining technical support or
the correct parts in the proper material of construction.
Figure 1. Remove dowel pins, set pins, and pull the cover over the piston rod.
ANNUAL SURVEY
As a result of the compression process, forces are generated that must be absorbed by the
compressor components. These forces are considered when a compressor is selected for an
application. Components such as balance pistons and bearings are optimized for the forces
created at the design conditions of service.
The twin screw compressor is simplistic in its basic design but precise in its execution. In
operation, the compressor is often subjected to system upsets and contamination in addition to
the design loads. These conditions have a continuous effect on the few normal-wearing
components. This inevitable wear, from conditions both obvious and unsuspected, is the reason
an internal inspection is needed regularly.
The purpose of the suggested annual survey is to check for significant wear of the thrust
bearings, slide valve guide block, or PTFE seals. The survey includes removing the hydraulic
cylinder, outlet end cover, and the slide valve. Key parameters for inspection include gauging the
rate of wear of the inspected parts.
This is the golden opportunity to troubleshoot any abnormal condition or high-wear-rate situation
and rectify the root cause.
One of the attractions of the rotary screw compressor is lack of contact and wear of the major
components. The basic compressor, if refurbished from time to time, can continue to perform its
intended duty indefinitely. This major advantage is largely lost if the normal-wearing
components are kept in service beyond their useful life.
When ignored or kept in service with clearances that are out of specification, the compressor is
in danger of being damaged to the point of being beyond financially reasonable repair.
Too often, the compressor “failure” is actually a human failure. Compressor failures that occur
due to accidents may not be avoidable; failures due to neglect are.
Disassembly:
1. Drain oil from the hydraulic cylinder, both sides of piston.
10. Fit the eyebolt to the outlet cover and support the weight.
11. Remove dowel pins, set pins, and pull the cover over the piston rod
(Figure 1). 12. Withdraw the slide valve (see Figure 2).
1. Insert a piece of 1/2-in. unscrewed rod into the discharge end of the rotor.
3. Using a push and pull action, record the indicator deflection (see Figure 3).
2. Set up a dial indicator on the casing; take readings from the 12 o’clock position of the rotor or
rotor locknut.
3. Insert a ½ -in. (13-mm) bar into the end of the shaft and lift (see Figure 4).
Rotors are pulled hard to outlet and checked for clearance (see Figure 5).
Compare those readings with published clearances (0.002-0.003-in. nominal, 0.004-in.
maximum).
Replace these parts and the O-rings during the annual overhaul.
2. Record component conditions and any additional observations. If readings are within
specification, the compressor can be reassembled using new O-rings, lockwashers, and PTFE
rings.
It is extremely important that the fasteners on the thrust-bearing retaining plates of the 163-mm
compressors are torqued exactly to the specified setting of 10 lb/ft. Over-torquing will not permit
correct operation on the thrust bearings, resulting in premature failure.
FAILURE ANALYSIS
Mechanical seal — The input shaft seal is the most precise and most fragile component of any
screw compressor. In many instances, it’s like the mine canary: It becomes the first point of
observable distress.
A key point is that multiple “seal failures” are rarely actual seal failures. What you are likely
observing is the proverbial tip of the iceberg; the leaking seal might be a warning of a more
deeply rooted problem.
Seal problems can be characterized as occurring in two general areas: primary face and
secondary seal. A few of the conditions you may observe and likely causes are listed in Table 1.
For repeated seal failures, don’t overlook the items listed in Table 2.
BEARINGS
A compressor’s bearings are among its most vital components. In addition to their antifriction
qualities, compressor bearings locate the position of the rotors with great precision.
Journal — The main bearing (hydrodynamic type) depends on a film of oil to keep the rotor and
bearing surfaces separated. This thin film supports the entire weight of the rotor and its gas load.
Bearings fail when this oil film becomes contaminated, breaks down, or if the bearing becomes
overloaded.
The oil film is created and maintained by the lube oil system. At rest, the rotor journal is in
contact with the bearing surface. With proper oil pressure, the rotor “floats” on the oil injected
into the bearing cavity. Under design loads, the rotor rides on a lubricant wedge. Under normal
operating conditions and a continuous supply of clean oil, the rotor and bearing surfaces remain
separated. (See Table 3 for a listing of journal problems and their causes.)
Rolling element — The thrust bearings installed in the WRV163 compressor are paired single-
row, angular-contact ball bearings. The steel-caged antifriction bearings are fitted face to face at
the discharge end of the compressor.
The bearings are off-loaded by the use of balance pistons and sleeves installed at the discharge
end of each rotor. Further off-loading of the male rotor thrust is achieved on some models by
having another balance piston in the mechanical seal cavity at the inlet end of the male rotor. The
163-mm compressor achieves sufficient off-loading by utilizing a single balance piston on the
input end of the male rotor. (See Table 4 for a listing of rolling element problems and their
causes.)
The term “lubrication failure” does not usually imply a total lack of lubrication. A thorough
investigation may reveal too low a differential oil pressure, improper viscosity due to dilution, or
product condensing due to a low discharge temperature.
Figure 3. Using a push and pull action, record the indicator deflection.
VIBRATION, NOISE
The inherent vibration and sound levels of a bare compressor are rather low. For the 163-mm
compressor, the maximum vibration level is 0.2165-in./sec in the horizontal and vertical plane
and 0.295-in./sec axially. These levels are measured in RMS velocity.
While sound levels are subjective, changes in operating sound levels should not be ignored. The
cause of abnormal sound/vibration levels can be rooted in the compressor drive, auxiliary
equipment, or system gas flow. Noise from the motor, piping, vessels, etc., will increase the
perceived sound pressure level in any installation, as will the acoustical environment and
background noise where the compressor is installed.
The conditions and causes listed in the previous failure analysis were kept simple. In reality,
several factors often seem to conspire, making the root cause of a failed component not always
obvious. Only after a complete review of operating conditions and other compressor components
can these be determined.
If it is determined that the compressor requires complete disassembly for repair or overhaul, the
following additional steps should be followed.
Figure 4. Insert a 1/2-in. (12-mm) bar into the end of the shaft and lift.
COMPLETE DISASSEMBLY
The following details the disassembly procedure for a major overhaul.
The snap rings retaining the journal bearing can be removed and the bearings
extracted.
Note: Assembly is performed in the reverse order, paying particular attention to published
torque values and recording all clearances.
Figure 5. Rotors are pulled hard to outlet and checked for clearance.
CLOSING THOUGHTS
Many internal components perform more than one function. Understanding their full
purpose will aid in troubleshooting.
Paying attention to detail and cleanliness is key.
Not performing routine inspections is shortsighted.
Widener is North American customer support manager for Howden Compressors, 1850B N.
Gravers Rd, Plymouth Meeting, PA 19462; 610-313-9800.
The existence of any of these conditions will not indicate the area of fault, but should be the
signal to perform an investigation to determine and rectify the root cause. Extra diligence
when performing the annual survey would also be wise.