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SELECTION OF SCREW COMPRESSORS FOR ENERGY EFFICIENT OPERATION

Reindl, Douglas T. and Jekel, T. B. [email protected] [email protected] Industrial Refrigeration Consortium University of Wisconsin-Madison Madison, WI USA ABSTRACT
Since compressors are the single largest consumer of primary energy (usually electricity) in an industrial refrigeration system, they often become a focal point for energy efficiency improvement strategies. Although a number of alternative compressor technologies are available including: reciprocating and rotary vane, many refrigeration end-users are gravitating toward specification and installation of screw compressors. This paper discusses the unique characteristics of screw compressors and criteria for selection to yield energy efficient operation when integrated into a built-up industrial refrigeration system. The paper begins with a brief overview of screw compressor technologies, methods of capacity control, and volume ratio concepts. Then, energy efficiency aspects of screw compressor technologies are discussed for both fixed and variable volume ratio configurations. Finally, guidelines for screw compressor selection are outlined.

INTRODUCTION
Screw compressors are increasingly becoming the standard compression technology for large industrial refrigeration systems. Today, single- and twin-screw compressor packages are available in sizes ranging from 372,237 kW [50 3,000 BHP] and their uses extend beyond commercial and industrial refrigeration to other applications such as gas compression and air compressors. Screw compressors offer several advantages over other compression technologies; however, there are a number of factors that need to be considered in the process of selecting a screw compressor that will lead to efficient refrigeration system operation. This paper focuses on evaluating the efficiency characteristics of both fixed and variable volume ratio designs at full-load and part-load conditions with an aim toward providing selection guidelines that support efficient refrigeration system operation.

1 SCREW COMPRESSOR VOLUME RATIO

By their very nature, screw compressors are fixed geometric compression devices. That is, a screw compressor achieves its objective of raising the pressure of a gas by trapping a fixed volume of gas on the suction side and progressively decreasing that volume of gas; thereby, raising its pressure at the discharge side. The ratio of the volume of gas trapped in the thread of the screw at the start of the compression process to the volume of trapped gas in the thread when it first begins to open to the discharge port is known as the compressors volume ratio or volume index, Vi (ASHRAE 1996). An analogy to this process would be reciprocating compressor with camoperated suction and discharge valves. In this analogy, the opening of the valves is purely a function of the piston position; therefore, the suction and discharge volumes are fixed. Screw compressor manufacturers have developed machines capable of varying the effective volume ratio both continuously during operation and incrementally by manual adjustment in the field. The general principle behind a variable volume ratio screw compressor is that the location on the screw at which the refrigerant vapor being compressed is allowed into the discharge port is movable. A compressor equipped with continuous volume ratio control, in effect, repositions the discharge port as the systems condensing pressure changes. For example when the compressor operates at a low condensing pressure condition, a volume ratio slide valve within the compressor will move in a direction toward the suction side of the screw. This relieves the trapped refrigerant vapor from the compressor earlier in the compression process before it has the opportunity to rise in pressure through a decrease in volume to a point that would result in overcompressing the gas. During high condensing pressure conditions, a International Congress of Refrigeration 2003, Washington, D.C. 1

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volume ratio slide valve moves away from the suction side of the compressor to delay the discharge of compressed gas until it reaches a higher pressure. The goal in varying the discharge volume is to match the pressure of the gas trapped in the rotor groove just prior to uncovering the discharge port with the prevailing system discharge or condensing pressure.

2 FIXED VS. VARIABLE VOLUME RATIO

The volume ratio of a screw compressor should be one of the factors considered when selecting a new compressor or modifying the operation of an existing screw compressor. Fixed volume ratio compressors offer the advantage of having lower capital cost, lower maintenance costs, and greater reliability; however, the chief disadvantage is diminished operational flexibility. In this section, we evaluate the operational disadvantage of fixed volume ratio screw compressors more closely to determine the extent it constrains or limits the energy efficient operation. Both full-load and part-load performance are considered. Since fixed volume ratio compressors are available in a finite number of increments, designers must be judicious in the process of compressor selection to achieve efficient operation upon integration into a system. To explore the influence of volume ratio on compressor efficiency under floating head pressure conditions, the full-load compressor package efficiency for five unique volume ratios (1.7, 2.2, 2.8, 3.0, 3.5, and 5.0) is compared for three separate saturated discharge temperatures (ranging from 35C [95F] to 24C [75F]) while operating at high and low suction temperatures: -7C [20F] and -29C [-20F]. Figure 1 below shows results of analyzing manufacturers performance data for a typical screw compressor operating at a saturated suction temperature of -7C [20F].

Figure 1: Influence of volume ratio on full-load efficiency for a fixed Vi compressor operating at -7C [20F] saturated suction temperature. For a fixed suction pressure, the compression ratio (and ideal volume ratio) changes as the discharge pressure varies. At this saturated suction temperature and a typical design condensing or head pressure of 1,248 kPa [181 psig] (which corresponds to a 35C [95F] saturation temperature), the compressor needs to develop a compression ratio of 4.06:1. At this condition, an ideal volume ratio for the screw compressor would be 2.74. The filled circle symbols in Figure 1 show the calculated ideal volume ratios for each condensing temperature case. The full-load performance at high suction temperatures is fairly insensitive to volume ratio over a broad range of fixed volume ratio choices. In this case, selecting a screw compressor with volume ratio of 2.8 would yield good performance over a wide range in condensing temperatures. International Congress of Refrigeration 2003, Washington, D.C. 2

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Figure 2 shows the full-load performance of a fixed volume ratio compressor operating at a fixed suction temperature of -29C [-20F] over a range of condensing temperatures. At condensing temperatures above 29C [85F], the ideal volume ratio exceeds the largest available volume ratio in this compressor series. Operating low volume ratio compressors (i.e. 1.7 or 2.2) under these conditions leads to significant performance penalties.

Figure 2: Influence of volume ratio on full-load efficiency for a fixed Vi compressor operating at a saturated suction temperature of -29C [-20F]. The previous efficiency results are all for fixed volume ratio compressors packages operating at full-load. As a screw compressor is unloaded, its efficiency decreases. Figure 3 shows part-load performance trends for a 18C [0F] saturated suction and 24C [75F] saturated discharge temperature. Under these conditions, the compressor operates at a compression ratio of 4.63:1 with an estimated ideal volume ratio of 3.34. At full load conditions, the best performing compressor, Vi=3.5, matches closely with the ideal volume ratio compressor; however, the efficiency of the compressor diminishes as it is unloaded. At full-load, the compressor package has an efficiency of 0.25 kW/kWT [1.19 BHP/ton]. When the compressor is unloaded to a part-load ratio of 0.5 (50% of full-load capacity), the efficiency degrades to 0.31 kW/kWT [1.48 BHP/ton] which represents a 25% increase in required horsepower for each ton of refrigeration. This reinforces the guidance to operate screw compressors at or near fullload as much as possible [Manske, et al. 2002].

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Figure 3: Compressor part-load efficiency for a range of fixed volume ratio compressors. Figure 4 illustrates the performance of fixed and variable volume ratio screw compressor selections operating over a range of saturated discharge temperatures for three separate saturated suction temperatures (-29C [-20F] to -7C [20F]). At a saturated suction temperature of -29C [-20F], the variable volume ratio compressor operates at the compressors maximum volume ratio (Vi=5.0 in this case). It is not until the saturated condensing temperature reaches 18C [65F] when the variable volume ratio compressor begins to offer any performance benefits. The efficiency advantage of the variable volume ratio over the fixed Vi compressor at this full-load condition is rather small. At a -7C [20F] suction temperature, the fixed Vi of 2.8 compares well with the variable volume ratio machine until low discharge temperatures are reached. The variable volume ratio machine then begins to exhibit an improvement in efficiency. At a -18C [0F] suction temperature and below 32C [90F] discharge, the fixed volume ratio compressor (Vi=3.0) compares favorably to the variable volume ratio compressor. The differences in performance between fixed and variable volume ratio are slight because the fixed volume ratio compressor has been selected to match its anticipated operating pressure (or saturation temperature) envelope. Without a careful selection of the compressors volume ratio, significant performance penalties will be assured. For example, a compressor selection with a fixed volume ratio at 2.2 operating at a suction temperature of -18C [0F] will result in an operating efficiency penalty at any condensing temperature above 20C [68F].

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Figure 4: Fixed and variable volume ratio full-load efficiency characteristics.

3 SELECTION CONSIDERATIONS
There are several factors that should be considered during the course of evaluating potential selections for a new screw compressor or changing the operating conditions of an existing screw compressor. Items that designers should considered include: 1. Expected range of operating suction and discharge pressures a. single stage or two stage operation (booster or high-stage) b. swing duty (boosters operating as a single (or high) stage) c. load variability over time (large pull-down loads vs. relatively constant loads) Climate type and system minimum head pressure constraints Oil separator sizing/selection Oil cooling methods System and package losses for check valves, service valves, strainers installed around the compressor Expected maintenance costs over machines life

2. 3. 4. 5. 6.

One of the key selection criteria is the expected operating suction and discharge pressures for the compressor. Many compressors operate with a fixed or relatively narrow compressor suction pressure (temperature); however, some compressors are designed for swing duty to serve loads at different suction levels. All compressors will operate over a range of discharge pressures and some will run over a wider range of discharge pressures due to seasonal fluctuations in condensing pressures. The greatest challenge for systems that operate over a wide range of condensing temperatures is selecting a fixed volume ratio screw compressor that can deliver a high level of energy efficiency. Table 1 below provides suggested volume ratio selections for fixed Vi compressors that will operate over high, medium, and low ranges in head pressure. In all cases, the data in Table 1 assumes that the maximum saturated condensing temperature is 35C [95F]; however, the minimum saturated condensing temperature varies from 18C [65F] to 27C [80F].

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Table 1: Fixed volume ratio screw compressor selection ranges. Head Pressure Range1 Saturated Suction High2 Medium3 Low4 Temperature C [F] 1,342 790 kPa 1,342 894 kPa 1,342 1,032 kPa [180 100 psig] [180 115 psig] (180 135 psig] -40 [-40] -29 [-20] -18 [0] -7 [20] 4 [40]
1

5.0 or higher 3.5 5.0 2.5 3.5 1.5 2.7 1.4 2.5

5.0 or higher 3.5 5.0 2.7 3.5 1.7 3.0 1.5 2.7

5.0 or higher 4.0 5.0 3.0 4.0 2.0 3.5 1.5 3.0

The head pressure range is defined as the difference between the maximum and minimum saturated condensing temperatures. 2 corresponding to a SCT ranging between 35 18C [95 65F] 3 corresponding to a SCT ranging between 35 21C [95 70F] 4 corresponding to a SCT ranging between 35 27C [95 80F] Ideal volume ratios for fixed Vi machines operating over a range of suction and discharge conditions were shown earlier in this paper. Below, Figure 5 shows ideal volume ratios for fixed Vi compressors operating under booster duty in two-stage compression systems. If a compressor will operate as a swing machine, select a variable volume ratio compressor due to its ability to deliver superior performance in comparison to its fixed Vi counterpart. If a compressor is expected to operate over a wide range of suction pressures (due to pull-down or process variability) select a variable volume ratio screw compressor.

Figure 5: Ideal volume ratios for booster compressors operating in two-stage compression systems. The condensing or head pressure of a system is dictated, in part, by the outside air wet bulb temperature. As the outside air wet bulb temperature decreases, the condensing temperature decreases until the systems minimum is reached. The minimum condensing temperature depends on a number of system-specific constraints such as: thermostatic expansion valves, hot gas defrost (main and run-out sizing, defrost relief regulator set points, gaspumping requirements, etc.), presence of liquid injection oil cooling, sizing of high pressure liquid lines, and others. International Congress of Refrigeration 2003, Washington, D.C. 6

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Figure 6 illustrates the theoretical frequency of saturated condensing temperatures for a system with a lower limit on condensing temperature constrained at 791 kPa [100 psig] (17C [63F]) in Madison, WI. The system would operate at its minimum condensing temperature for 3,925 hours (45% of the time) during the year. For fixed volume ratio machines, select a volume ratio that will match the suction and discharge conditions expected during the majority of yearly operating hours but check to be sure it will meet the peak load requirements at design conditions.

4000

Madison, WI
3500

3000

Hours per Year

2500

Dry Operation Wet Operation

2000

1500

1000

500

0 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95

Saturated Condensing Temperature [F]

Figure 6: Frequency analysis of theoretical condensing temperatures for an evaporatively condensed industrial refrigeration system in Madison, WI. In the course of selecting a screw compressor for peak performance during off-design conditions, oil separator sizing becomes important because the full-load volume flow rate of gas at the discharge of the compressor will slightly increase as the head pressure decreases. The discharge volume flow rate will also increase slightly with an increase in suction pressure. Both of these increases in volume flow rate are due to an increased volumetric efficiency as the compression ratio decreases. Any increase in the volume flow rate will result in an increase in the mass flow rate of refrigerant through the compressor. In addition to the increased volume flow rate, as the suction pressure increases the suction vapor density increases resulting in a larger mass flow rate of refrigerant for the same volume flow rate. Individually or combined, lowering condensing pressures and raising suction pressures are two widely pursued strategies for effectively improving the energy efficiency of refrigeration systems. Both have the net effect at increasing the mass flow rate of gas through the compressor and through the oil separator. A decrease in discharge pressure results in a decrease in vapor density, which means that for a given mass flow rate through the compressor the discharge volume flow rate increases. If the discharge volume flow rate through the separator exceeds the rate assumed in the sizing of the separator, the efficiency of oil separation will decrease. As the oil separation efficiency decreases, the concentration of oil leaving the separator and migrating out into the system will increase. This results in the need for greater frequency of oil draining from points out in the system. Select the oil separator for full-load operation at the maximum expected suction pressure coincident with the lowest expected discharge pressure. The choice of oil cooling methods also influences the compressor efficiency. Oil cooling can be accomplished either internal or external to the compressor. Internal oil cooling is commonly called liquid injection oil cooling and is accomplished by injecting high-pressure liquid ammonia into the body of the compressor to absorb a portion of the heat of compression; thereby, maintaining cool oil temperatures. The discharge temperature of the refrigerant vapor and oil is controlled to maintain the required oil supply temperature. Liquid injection oil cooling is the lowest capital cost option for screw compressor oil cooling; however, it results in a loss of compressor capacity and necessitates a higher minimum head pressure to maintain the required pressure differential across the oil cooling thermostatic expansion valve to maintain control authority.

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External oil cooling requires a heat exchanger to cool the oil outside of the compressor. As such, the discharge temperature will be higher than the oil supply temperature. The most common arrangement for external oil cooling uses high-pressure liquid refrigerant in a thermosiphon arrangement. Thermosiphon oil cooling is the most efficient and lowest compressor maintenance cost option but has the largest capital cost. The payback thermosiphon oil cooling is often less than 3 years. A capital investment in thermosiphon oil cooling is money well spent. It is worthwhile to recognize that the selection of components around the compressor itself will influence its efficiency when integrated into the system. All compressor manufacturers have provisions for selecting alternative trim components including service valves, check valves, and strainers. Those options include low pressure drop components for minimum parasitic losses. Be sure to look at the difference in compressor performance with and without low pressure loss trim. Finally, maintenance costs for compressor selections should be included with energy costs in the economic analysis of alternatives being considered. In general, maintenance costs for liquid injection oil cooled compressors are greater than their external oil cooled (thermosiphon or water-cooled) counterparts. Maintenance costs for variable volume ratio screw compressors are higher than fixed volume ratio machines. The increased maintenance costs for variable volume ratio screw compressors are attributed to the additional components needed for volume ratio control.

4 CONCLUSIONS
With a proper choice of volume ratio, fixed volume ratio compressors offer good energy efficiency performance as system head pressure floats to achieve efficient system operation. Variable volume ratio machines will deliver improved energy performance over a wide operating envelope but a price is paid for that benefit. Variable volume ratio compressors have slightly higher capital costs, increased maintenance cost, and reduced reliability when compared to their fixed Vi counterparts. The increased maintenance costs and reduced reliability are attributed to the additional components needed for volume ratio control. If you have an opportunity, perform a life-cycle analysis for alternative compressor selections. The life-cycle cost should include capital, operating, maintenance, and replacement costs over a specified time period. Keep in mind that, based on evidence from the field, some ancillary equipment alternatives (such as liquid injection oil cooling) will lead to shortened compressor lifetimes when compared to others (such as thermosiphon oil cooling).

NOMENCLATURE
CR k SDT SST Vi Vi,ideal compression ratio (ratio of the absolute pressure at the discharge to the pressure at suction) ratio of specific heats (constant pressure to constant volume) saturation temperature corresponding to the compressor discharge pressure saturation temperature corresponding to the compressor suction pressure compressor volume index (ratio of gas volume trapped on the suction side to the discharge side) ideal volume ratio based on the required compression ratio in accordance with the relationship Vi=CRk

REFERENCES
ASHRAE, Handbook of HVAC Systems and Equipment, American Society of Heating Refrigerating and Air Conditioning Engineers, Atlanta GA, (1996). Manske, K. A., Klein, S. A., & Reindl, D. T., Load Sharing Strategies In Multiple Compressor Refrigeration Systems, ASHRAE Transactions, Vol. 108, Pt. 1, (2002).

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