COMPRESSORS
Screw compressor support for contractors
Tackling screw compressors in the fi eld can be daunting. Will Pribyl, general manager of Green Point UK, highlights some key issues to be aware of and reports on a new support service for contractors.
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The need for greater effi ciency to reduce carbon emissions and cut end users’ energy costs is also stimulating demand for screw-based systems.
crew compressors are effi cient workhorses for larger-scale cooling applications and are increasingly coming to the fore as their range of applications grows. Screw-based heat pump systems and reverse cycle chillers are increasingly being used in large heating and cooling projects, such as district schemes and heat networks. They are not only compatible with a wide range of very low global warming potential and natural refrigerants, but screw compressors are also designed for heavy-duty use and tend to have longer lifespans, making them a more sustainable choice in terms of embodied carbon and lifetime costs. This durability reduces the need for replacements, which in turn lowers the environmental impact of manufacturing and transporting new units.
Set up properly, screw compressors are very energy effi cient, particularly when equipped with variable speed drives. The need for greater effi ciency to reduce carbon emissions and cut end users’ energy costs is also stimulating demand for screw-based systems. For these reasons, many fi eld engineers in the future may be encountering sophisticated screw technology for the fi rst time. It is a world away from conventional reciprocating technology and sealed hermetics. While small hermetics are simply scrapped at the end of their life, wasting carbon and materials, reciprocating compressors are accessible in the fi eld and better understood, as the technology is based on similar principles to piston-based automotive engines. In contrast, modern screw compressors operate on diff erent mechanical principles and are made using advanced manufacturing techniques to achieve the extremely
fi ne tolerances required. Opening up and getting hands-on with such equipment can be intimidating for service engineers, particularly given the potential consequences of extended downtime or permanent damage. A key technical aspect of screws is the precision required in their manufacture and their tight mechanical tolerances. Even minor wear or misalignment can lead to signifi cant performance issues. Field engineers have to be extremely precise and careful in carrying out work, which sometimes requires special tools. Proper sealing and lubrication are critical to operation, and seal failure or inadequate lubrication can result in severe damage. Engineers need in-depth knowledge of the correct types and amounts of lubricants and how to apply them. Engineers need to be aware of how operating conditions, including temperature and environmental factors, can aff ect compressor performance and longevity, and how to adjust maintenance practices accordingly. Screw compressors are often large and heavy, making handling in the fi eld a challenge. Special lifting equipment or techniques may be needed to manage units safely during servicing, and this may not be standard-issue kit for many fi eld engineers.
Due to their sophisticated design, identifying potential issues within a screw compressor may require advanced diagnostic equipment and techniques. Engineers need to be skilled in using such tools, which may involve interpreting vibration analysis, oil analysis, or thermography results to detect problems within the compressor. Screw compressors are often part of larger, integrated cooling or heat pump systems. Problems in the compressor can aff ect other parts of the system and vice versa.
16 November 2024 •
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