Solving the task of import substitution of screw refrigeration compressor repairing

BACKGROUND: This article presents the experience of 'Engineering Technological Solutions' in the field of reverse engineering of screw compressors based on the methodology of adaptive recalculation of rotor meshing. This approach allows designing rotor pairs compatible with existing compressor housings without compromising key performance characteristics. The results of the Howden WRVi compressor reengineering projects are presented. One of the factors confirming the recalculation accuracy is the compressor flow coefficient, which shows a minimal deviation from the original values.

AIM: to evaluate the possibility of reengineering screw rotor pairs using adaptive recalculation methods.

METHODS: The lack of original spare parts compromises the reliability of equipment and forces companies to seek import substitution solutions. The article describes an adaptive recalculation methodology that takes into account not only the geometry of the original rotors, but also a number of operational factors. Examples of successful compressor reengineering projects are given, and the validity of the solutions is confirmed by analysis and comparison of flow coefficients.

RESULTS: Engineers at 'Engineering Technological Solutions' have developed design documentation for screw rotors. The components were calculated using an adaptive recalculation methodology. Currently, these rotor pairs are in the industrial production stage. The application of the proposed method for recalculating the geometry of screw rotors led to a change in their profile. At the same time, the key operational characteristics of the compressors were maintained at the initial level. Analysis of the flow coefficient λ shows that the new calculated value has minimal deviations of more than 2% from the initial parameter, which further confirms the accuracy of the calculations.

CONCLUSIONS: The studies conducted confirmed the feasibility of re-engineering screw rotor pairs using the adaptive recalculation methodology. The minimal deviations in the flow coefficient indicate that the modernised rotors maintain the operating parameters of the compressors at the level of the original units. The redesign of the rotor structure ensured the technological feasibility of manufacturing rotor pairs using existing Russian production capacities, which makes the proposed approach an effective tool for import substitution.