DOUBLE STAGE AIR

COMPRESSOR
Instruction Manual

CREATIVE LAB
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 DOUBLE STAGE AIR COMPRESSOR

OBJECT: To study the operation of a double stage air compressor.

AIM:
To find out the volumetric efficiency
To find out isothermal efficiency
To calculate the compression ratio

INTRODUCTION:
Air Compressor is a device, which sucks the air from atmosphere and compresses it
and delivers in reservoir tank. It compresses the air by means of a reciprocating
piston, which reciprocates in a stationary cylinder. It can be single stage or multi
stage. It can be single acting or double acting.

THEORY:
In two-stage compression, air is partially compressed in low-pressure cylinder. This
air is passed through cooler between first stage and second stage so that air at inlet
of second stage is at lower temperature than the first stage outlet. This is done to
reduce the work of compression in second stage. Final compression is completed in
second stage i.e. in high-pressure cylinder. Also, the compressors are provided with
clearance volume, two stage compressors can achieve higher volumetric efficiency
than single stage compressors, because of lower compression per stage. As the
compressed air is used in a wide range in industrial, domestic, aeronautics fields
etc. so compressors are applied in wide range. Compressors are used where the air
is required at high pressure.
DESCRIPTION:

Double stage air compressor test rig consists of two cylinders and piston, a reservoir
tank. Driven by A.C. motor. Temperature sensors are provided at inlet and outlet. To
find out the inlet volume of air, an orifice meter is provided. Pressure Gauge is
provided at reservoir tank. Safety valve and auto power out switch is provide for the
safety factor.

UTILITIES REQUIRED:
1. Electricity Supply: Three Phase, 440 VAC, with earth connection.
2. Floor Area Required: 1.5m x 0.75 m

EXPERIMENTAL PROCEDURE:

1. Close the outlet valve of tank and start the compressor.

2. Let the receiver pressure rise up to around 2 kg /cm 2. Now open the delivery
valve so that constant delivery pressure is achieved.
3. Wait for some time and see that delivery pressure remain constant. Now note
down the pressure.
4. Record the time for 10 pulses of energy meter.
5. Record the manometer reading.
6. Record the temperature of air at inlet, before second stage and after second
stage.
7. Find out the RPM of compressor with the help of RPM indicator.
8. Repeat the same procedure for different delivery pressure.
STANDARD DATA:

 Bore Diameter, d of cylinder = 78 mm

 Length of stroke, L = 93.5 mm
 Diameter of orifice, do = 12 mm
 Cross- sectional area of orifice, ao = 1.13×10-4 m2
 Diameter of pipe, dp = 25
 Cross- sectional area of pipe, = 4.91×10-4 m2
 Density of water, m = 1000 kg/m3
 Density of air at 0o C i.e. 273o K a = 1.293 kg/m3
 Co-efficient of discharge Cd = 0.64
 Energy meter constant, E.M.C = _____ Pulses/KW-hr
 Atmospheric pressure, Pa = 1.013 Kg/cm2 = 1.013x105 N/m2

OBSERVATION TABLE:

Manometer Gauge No. of Pulses Time Taken

N Reading Pressure of Energy for P Pulses tp
S.N.
(RPM) Reading Meter (sec)
h1 h2 (kg / cm2) (P)
 FORMULAE:
h1  h2
h ,m
100
 
H   w  1  h , m of air
 a 

 2
ao  d o , m2
4
 2
a P  d P , m2
4

ao a p
Qa  C d 2 gH , m3/sec
a 2p  ao2

 d2 L N
Qt  , m3/sec
60  4

Qa
v   100%
Qt
P  3600
Ei  , KW
t p  EMC
Pd  Patm
r
Patm
Q  log r  Patm
Eiso  a , KW
1000
E
 iso  iso  100%
Ei

CALCULATION TABLE:
S. N Head Q act Qt Electrical Volum. Comp. Isothermal Isothermal
N. (RPM) H(m) m 3/sec m 3/sec Input Eff. Ratio Power Effi.
(Watt) η vol (%) r (Watt) η iso (%)

NOMENCLATURE:
 N : RPM (Rated Speed) of Compressor.
EMC : Energy Meter Constant
Cd : Discharge Coefficient of Orifice =0.64
ao : Cross Sectional Area of Orifice, m2
ap : Cross Sectional Area of Pipe, m2
g : Acceleration due to Gravity = 9.81 m/s2
H : Air Head Causing Flow
ρw : Density of Water =1000 kg/m3
ρa : Density of Air =1.205 kg/m3
h : Differential Manometer Reading.
Qact : Actual Discharge,m3/sec .
Qt : Swept Volume per second,m3/sec .
r : Compression Ratio.
ηvol: Volumetric Efficiency.
ηiso : Isothermal Efficiency.
P : Pulses of Energy Meter.
tp : Time for pulses, sec.
L : Length of Compressor Cylinder (Stroke)
d : Diameter of Compressor Cylinder (Bore)
Pact : Actual Pressure of Discharge

PRECAUTIONS AND MAINTENANCE INSTRUCTIONS:

1. Check the Oil before starting the Air Compressor
2. Check the proper voltage while conducting experiments.
3. Be Careful while measuring the RPM
4. Close the delivery valve of Tank before starting the experiments.
TROUBLESHOOTING:
1. If Control Panel does not show input, check fuse and main supply.
2. If Pressure gauge is not showing the pressure, there may be a leakage of air.
Check the suction line and valves provided on delivery line.
3. If Manometer is not showing the pressure difference, check the orifice plate
and suction line.