Indian Journal of Pure & Applied Physics

Vol. 49, January 2011, pp. 35-41

Condition monitoring of reciprocating air compressor using IR thermography

S S Singh & A K Singh*
Department of Aerospace Engineering, Defence Institute of Advanced Technology (Deemed University), Girinagar, Pune 411 025
*E-mail: draksingh@hotmail.com; aksingh@diat.ac.in
Received 17 January 2010; revised 24 September 2010; accepted 9 November 2010

The usage of IR thermography as an effective condition monitoring tool on reciprocating air compressor has been
studied. The technique allows monitoring of temperatures and thermal patterns while the equipments are running. The
compressor cylinder fins tip temperatures are measured using infrared gun and thermocouple and have been further analysed
by finite element method. Based on experiments and finite element analysis, equation is generated for internal surface
temperature rise in the compressor cylinders due to running of the compressor. The analysis involved correlating the surface
temperature with that obtained by finite element analysis. It is, further, highlighted in the paper that as the compressor under
study does not cater for any kind of temperature measurement to analyse the performance of compressor, thermal imaging of
such equipments can be beneficial in analysing the health of the equipments by acquiring thermal images over a specified
interval of time which could be time specific.
Keywords: Finite element analysis, Infrared, Thermograph, Thermocouple, Steady state

1 Introduction
Infrared thermography is now being targeted as a
versatile tool for condition monitoring of
equipments1,2. Infrared imaging will help quickly and
efficiently find the areas that are most in need of
maintenance. The infrared thermal imaging method
utilizes the radiant existence in the infrared spectral
band from measured objects to measure temperature.
It is non-intrusive, applicable remotely and suitable
for measurement3 of a large area, and can also serve
to record data for subsequent storage and processing
with a PC. Ay et al.4 used an infrared thermal imaging
camera to observe the surface temperature of a plate
finned-tube heat exchanger and calculated the local
heat transfer coefficient. IR thermography on
equipments shows that the surface thermal patterns
are a consequence of internal conditions. Basic aim of
this study is to maintain the equipments by evaluating
its performance at specified interval of time. Using
finite element analysis5,6, we have shown that the
internal conditions can be evaluated from the external
surface conditions.
The purpose of this study is to determine the
applicability of IR thermography as a condition
monitoring tool and also to evaluate inner surface
temperature rise during compressor operation.
2 Instrumentation
To perform experiments reciprocating air
compressor ELGI THPC 500 unit consisting of two
sets of cylinders; one for high pressure and other for
low pressure has been used. A portable Thermal
Imaging camera (EEV make, Model P 4430) has been
used for thermal imaging. It incorporates a video
output which can be used for direct recording to a
computer. The P4430 is a hand-held thermal imaging
camera with pyroelectric vidicon detector having
spectral response of 8-12 m. It is a self-contained
battery/ac power operated unit incorporating a
miniature display monitor and can be fitted with
interchangeable lens (Focal length 50/75 mm f 0.8)
and angle of view 17/11 deg. The equipment is for
general thermal imaging applications and gives
monochrome thermal pictures. The external video
signal is 1 volt 625 lines 50Hz (CCIR compatible) or
525 lines 60 Hz (optional), 30 frames / s and 200 lines
per picture height for a temperature difference of 2C
(chopped) and 1C (panned). A personal computer
having Q motion card for image acquisition and
WINVIDEO with Windows operating system has
been used.
An IR thermometer gun OPTEX THERMO-
HUNTER make (Model Q185) is used for direct
temperature reading of the object surface having
provision of emissivity adjustment. The temperatures
have been measured using T type thermocouples. For
the purpose, a data acquisition system using GENIE
software comprising ADAM 4018 and ADAM 4520
data acquisition modules is used. The camera was
calibrated with a hot plate (top surface cast iron)
36 INDIAN J PURE & APPL PHYS, VOL 49, JANUARY 2011

having built-in heater and temperature controller and 3 Experiments on Compressor

surface temperature was measured with t type The reciprocating air compressor ELGI THPC 500
thermocouples, placed on the top surface and IR unit consists of two sets of cylinders; one for high
temperature gun for calibration and comparison pressure (Fig. 1) and other for low pressure (Fig. 2).
purpose. These are fitted in V-configuration on a crankcase.
The fin tip temperature is measured using infrared The first stage compression end temperature amounts
thermometer for all the fins on both cylinders. The to 70C while second stage amounts to 140C. The
thermocouple is placed at fin tip for fins 1, 3, 6 and 8 heat dissipation is through circular fins of reducing
for low pressure cylinder and 1, 3, 6 and 9 for high areas. The set-up for the thermal imaging of
pressure cylinder as numbered from top. The compressor cylinders is shown in Fig. 3. The thermal
measured values as obtained using infrared images have been acquired in two phases. The first
thermometer and thermocouple for both the cylinders phase incorporated acquisition of thermal images of
are presented in Tables 1-4. The temperature scaling low pressure cylinder for seven minutes of
of the thermographs has been done by interpolating compressor running with images acquired for every
the gray scale value of the portion of the image to the minute of compressor running. The second phase
temperature range as obtained by the infrared incorporated acquisition of thermal images of high
thermometer. pressure cylinder for seven minutes of compressor
Table 1 IR Temperature at fin tips of LP cylinder
IR Temperature (oC )
Fin no 1min 2min 3min 4min 5min 6min 7min
No1 22.0 24.0 28.0 30.5 32.5 34.5 37.5
No2 22.0 24.0 26.5 30.0 32.0 34.0 37.0
No3 21.5 23.8 26.5 29.0 31.5 34.0 36.5
No4 21.5 23.8 25.5 28.5 31.0 33.8 36.3
No5 21.4 23.7 25.5 28.5 31.0 33.8 36.0
No6 21.4 22.6 24.5 28.0 30.8 33.6 36.0
No7 21.3 22.4 24.0 27.0 30.5 33.2 35.5
No8 21.3 22.2 24.0 26.0 30.0 33.0 35.0
No9 21.0 22.0 23.0 25.0 29.0 31.0 33.5

Table 2 Thermocouple temperature at fin tips of LP cylinder

Thermocouple Temperature (oC )
Fin no 1min 2min 3min 4min 5min 6min 7min
No1 21.26 23.55 27.13 29.03 31.907 33.686 37.107
No3 21.26 23.52 25.57 28.48 31.44 33.596 36.387
No6 21.23 22.46 25.22 27.51 30.637 33.426 35.657
No8 21.23 21.94 23.844 25.69 30.00 32.906 34.576
Table 3 IR temperature at fin tips of HP cylinder
IR Temperature (oC )
Fin no 1min 2min 3min 4min 5min 6min 7min
No1 28.0 29.0 31.0 36.0 42.0 48.0 55.0
No2 28.0 29.0 31.0 34.5 40.0 44.0 50.0
No3 27.8 28.5 30.5 34.5 37.5 39.0 40.0
No4 27.8 28.5 30.5 33.5 36.5 37.5 39.5
No5 27.6 28.3 30.5 33.0 36.0 36.5 39.0
No6 27.6 28.2 30.2 31.0 34.0 35.0 38.5
No7 27.6 28.2 30.2 30.5 34.0 35.0 38.0
No8 27.4 28.0 30.0 30.5 33.5 34.0 38.0
No9 27.4 27.5 30.0 30.5 33.0 33.5 37.5
No10 27.2 27.5 29.5 30.0 31.0 33.0 36.0
No11 27.0 27.5 29.0 29.5 30.0 32.0 35.5
 SINGH & SINGH: CONDITION MONITORING OF RECIPROCATING AIR COMPRESSOR 37

Table 4 Thermocouple temperature at fin tips of HP cylinder

Thermocouple Temperature ( oC )
Fin no 1min 2min 3min 4min 5min 6min 7min
No1 27.86 28.65 30.92 35.57 41.24 47.42 53.65
No3 27.74 27.92 30.72 33.53 35.72 38.36 39.77
No6 27.48 26.98 28.62 30.89 33.16 33.62 37.64
No9 27.33 26.72 28.12 30.55 32.99 33.36 37.56

Fig. 3 Experimental set-up on compressor

4 Modelling and Analysis in ANSYS

Fig. 1 High pressure cylinder
Fig. 2 Low pressure cylinder
running with images acquired for every minute of
compressor running. The thermal images of high
pressure and low pressure cylinders for alternate
minutes are shown in Fig. 4.
The cross-section of cylinders is modeled as per
dimensions taken from instructional manual of the
compressor. The model development and analysis has
been carried out in Ansys software Version 8.0
environment. The material of the cylinders is cast iron
of thermal conductivity 50 W/mK, density 7.272
kg/m3 and specific heat7 420 J/kg K, taken in the
analysis. The cylinders have been meshed using
PLANE 77 element. A transient conduction and
convection analysis has been carried out to generate
the fin tip temperature. A convection coefficient7,8 of
45W/m2 K has been used on the outer surface of the
cylinders for analysis. The point of application of the
thermal load has been evaluated by selecting the point
of stroke length at which the delivery valve opens and
to the point at which end of piston stroke occurs. The
maximum temperature rise occurs within this portion
of the cylinder and the inner cylinder surface
temperature rises over a period of time due to hot
compressed air and piston friction. At the outer
surface, heat is dissipated to the environment via
circular fins of varying sizes from top to bottom. The
analysis is based on the evaluation that the outer
surface temperature is a function of inner surface
temperature and higher the outer surface temperature,
38 INDIAN J PURE & APPL PHYS, VOL 49, JANUARY 2011

Fig. 4 Thermographs of HP and LP cylinders

it will be an indication of higher inner temperature
rise. In accordance with the compressor manual, the
first stage compression end temperature reaches
70 deg and second stage reaches 140 deg. The rise in
temperature happens over a span of compressor
operation. The IR gun and TC which give the fins
temperature at different timings of operation is taken
into account as reference during analysis in ANSYS.
The thermal load is applied to modeled cross-section
at an assumed value which would generate the fins tip
temperature to the nearest values as obtained by IR
gun and TC. The point of application of thermal load
has been considered by selecting the point of stroke
length at which the delivery valve opens and to the
 SINGH & SINGH: CONDITION MONITORING OF RECIPROCATING AIR COMPRESSOR 39

Table 5 FEA temperature (C ) at fin tips of LP cylinder

Fin no 1min 2min 3min 4min 5min 6min 7min
No1 22.227 23.365 26.549 29.505 32.463 35.648 39.287
No2 22.227 23.365 26.549 29.505 32.463 35.648 39.287
No3 22.182 23.092 25.641 28.007 30.374 32.923 35.835
No4 22.137 22.82 24.732 26.508 28.284 30.197 32.383
No5 22.091 22.547 23.824 25.009 26.195 27.472 28.931
No6 22.091 22.547 23.824 25.009 26.195 27.472 28.931
No7 22.091 22.547 23.824 25.009 26.195 27.472 28.931
No8 22.091 22.547 23.824 25.009 26.195 27.472 28.931
No9 22.091 22.547 23.824 25.009 26.195 27.472 28.931

Table 6 FEA temperature (C ) at fin tips of HP cylinder

Fin no 1min 2min 3min 4min 5min 6min 7min
No1 28.076 29.712 31.115 36.023 41.164 47.708 54.719
No2 28.076 29.712 31.115 36.023 41.164 47.708 54.719
No3 26.923 28.248 29.384 33.36 37.525 42.826 48.506
No4 26.923 28.248 29.384 33.36 37.525 42.826 48.506
No5 25.769 26.783 27.653 30.697 33.886 37.944 42.293
No6 24.165 25.319 25.922 28.034 30.246 33.062 36.079
No7 24.165 25.319 25.922 28.034 30.246 33.062 36.079
No8 24.165 25.319 25.922 28.034 30.246 33.062 36.079
No9 24.165 25.319 25.922 28.034 30.246 33.062 36.079
No10 24.165 25.319 25.922 28.034 30.246 33.062 36.079
No11 24.165 25.319 25.922 28.034 30.246 33.062 36.079
Table 7 Comparison of temperature (C ) at Fin No 1 of LP cylinder
1min 2min 3min 4min 5min 6min 7min
IR 22.0 24.0 28.0 30.5 32.5 34.5 37.5
TC 21.26 23.55 27.13 29.03 31.907 33.686 37.107
FEA 22.227 23.365 26.549 29.505 32.463 35.648 39.287
Assumed Inner Temp 22.5 25.0 32.0 38.5 45.0 52.0 60.0

Table 8 Comparison of temperature (C ) at Fin No 1 of HP cylinder

1min 2min 3min 4min 5min 6min 7min
IR 28.0 29.0 31.0 36.0 42.0 48.0 55.0
TC 27.86 28.65 30.92 35.57 41.24 47.42 53.65
FEA 28.076 29.712 31.115 36.023 41.164 47.708 54.719
Assumed Inner Temp 35.0 38.5 41.5 52.0 63.0 77.0 92.0

point at which end of piston stroke occurs. The inner
surface thermal load and subsequent fin tip
temperature to the nearest value with the ones as
obtained by IR temperature gun and thermocouple,
are analyzed for given duration of compressor
running. The various analytical results as evaluated
have been presented in Tables 5 and 6 and the FEM
analysis of both the cylinders for alternate minutes
have been shown in Fig. 5.
temperatures as obtained from IR thermometer,
thermocouple and FEA is presented in Tables 7 and 8
and the results are plotted in Figs 6 and 7.
The Inner Surface Temperature for LP Cylinder can
be evaluated as a function of time (t) in minutes of
operation by using the following relation:
Inner temperature (C) = 0.0694 (t)3 + 1.1607 (t)2
+ 0.9444 (t) + 20.071

5 Results and Discussion The Inner Surface Temperature for HP Cylinder

The maximum accuracy is analysed for topmost can be evaluated as a function of time (t) in minutes
fin. The comparison drawn for maximum fin of operation by using the following relation:
40 INDIAN J PURE & APPL PHYS, VOL 49, JANUARY 2011

Fig. 5 FEM analysis of HP and LP cylinders

 SINGH & SINGH: CONDITION MONITORING OF RECIPROCATING AIR COMPRESSOR
Fig. 6 Comparison of maximum fin temperature of LP cylinder
Fig. 7 Comparison of maximum fin temperature of HP cylinder
Inner temperature (C) = 0.0833 (t)3 + 2.3512 (t)2
4.6012 (t) + 37.714
6 Conclusions
The thermal images of both the cylinders show
variation in intensity due to rising surface temperature
over a span of compressor operation. The compressor
under study does not cater for any kind of temperature
measurement to analyse the performance of
compressor and hence, thermal imaging of the
41
equipment can be beneficial in analysing the health
of the equipment by showing similar thermal images
over a specified interval of time which could be as per
schedule may be quarterly or half-yearly or depending
on the usage of the equipment. In case, the thermal
images show a different thermal profile then further
investigations can be initiated to identify the possible
causes for different thermal pattern. For the cases
where thermal patterns are found to be same then
certain maintenance routines can be rescheduled
which will be cost-effective in terms of manpower
and spares replacements.
Acknowledgement
Authors are thankful to Vice-Chancellor, Defence
Institute of Advanced Technology (Deemed
University), Girinagar, Pune 411025 for granting
permission to publish this work.
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