Lab Session # 02

2.1 Objective
Investigation of variation of air flow rate with compressor ratio (without intercooling)
2.2Apparatus
Two stage reciprocating compressor
2.3 Main Parts of Reciprocating Compressor
1. 1st stage compressor
2. 2nd stage compressor
3. Intercooler
4. Pressure gauges
5. Water purge valve
6. Rota-meter

Figure 1Two stage reciprocating compressor

2.4 Procedure
Procedure starts by entering fresh air from any source first ally at the inlet of first compressor and
conditions like temperature pressure are noted at that condition compressor increase the pressure
of air, after this output of this air is used as input of second compressor second compressor
increases pressure mire to a higher value than first one. Note temperature and pressure readings at
this condition
2.5 Theory
2.5.1 Air Compressor:
A machine suck low pressure low temperature air from atmosphere and compresses it to high
pressure and high temperature by reciprocating motion of compressor is called a compressor.
2.5.2 Working Principal:
Work must be done upon the gas by an external agency. An air compressor takes in air at
atmospheric pressure, compresses it at the cost of the work supplied, and delivers the high pressure
air to a storage vessel called receiver from which it may be conveyed by the pipe line to a place
where the supply of compressed air is required.
2.5.3 Why do we use Compressed air?
The normal state of air, barometric, is called atmosphericpressure. When air is compressed, it is
under pressure greater than that of the atmosphere and it characteristically attempts to return to its
normal state. Since energy is required to compress the air that energy is released as the air expands
and returns to atmospheric pressure.
Our ancestors knew that compressed air could beused for power when they discovered that internal
energy stored in compressed air is directly convertible to work. Air compressors were designed to
compress air to higher pressures and harness that energy.
2.5.4 Following advantages of compresses air are as follow:
• Compressed air produces smooth translation with more uniform force
• Air does not possess the potential shock hazard of electricity or the potential fire hazard of oils.
• It is a utility that is generated in-house, so owners have more control over it than any other
utility.
• It can be used to push a piston, as in a jackhammer.
• Compressed air provides torque and rotation power for pneumatic tools, such as drills, brushes,
nut runners, riveting guns, and screwdrivers.
• Common applications is to cool large buildings.
• To operate lift, reams and pump.
• In paint spraying and in air conveying, the dynamic pressure of the air imparts motion.
2.5.5 Types of Compressor:

Figure 2 Types of Compressor

2.5.6 Positive Displacement Compressor:
In positive displacement type compressors, compression is achieved by trapping air into an
enclosed space and then reducing its volume. Since a fixed amount of air is trapped each time,
its pressure rises as its volume is reduced. When the pressure rises to the required level, then
 it is expelled from the enclosed space and a fresh charge of low-pressure air is drawn in and
the cycle continues. Since the flow of air to the compressor is not steady, the positive
displacement type compressor is a pulsating flow device. However, since the operating speeds
are normally very high the flow appears to be almost steady on macroscopic time scale.
Depending upon the construction, positive displacement type compressors can be classified
into:

• Reciprocating type
• Rotary type with sliding vanes (rolling piston type or multiple vane type)
• Rotary screw type (single screw or twin-screw type)

a) Reciprocating compressors:
Reciprocating air compressors compresses air in a cylinder by reciprocating motion of piston and
supplies high pressure air with intermittent discharge. Rotary compressors have compressed air at
low pressure but with continuous and high discharge. Reciprocating air compressors may be single
acting or double acting.

Reciprocating compressors consist of a piston moving back and forth in a cylinder, with suction
and discharge valves to achieve suction and compression of air. Its construction and working are
somewhat similar to a two-stroke engine, as suction and compression of air are completed in one
revolution of the crank. Reciprocating air compressors are positive displacement machines,
meaning that they increase the pressure of the air by reducing its volume. This means they are
taking in successive volumes of air which is confined within a closed space and elevating this air
to a higher pressure. The reciprocating air compressor accomplishes this by a piston within a
cylinder as the compressing and displacing element
Single Stage Compressor:
Construction:
Itconsists of cylinder and piston assembly. Assembly of crank shaft and connecting rod. Inlet and
delivery valve etc.
Working:
• The single stage reciprocating compressor is shown in figure 3.
• The single stage reciprocating compressor working is same as engine.
• During the downward motion of the piston the pressure iside the cylinder falls below the
atmospheric pressure and inlet valve is opened due to pressure.
• The air is taken into the cylinder until the piston reaches bottom dead positions
• As the piston starts moving upward, the inlet valve is closed and the pressure is increasing
continuously until the pressure inside the cylinder is above the pressure of delivery side which
to the receiver.
• Then delivery valve open and air transfer to receiver.
• This cycle is repeated.
Figure given below shows the schematic of a single stage reciprocating air compressor.
 Figure 3 Single Stage Compressor

b) Multi Stage Compressor:

Construction:
It consist of two cylinders, one is low pressure and another is high pressure.
Two parallel cylinders are connected by inter-cooler.
Working:
• compressed to final pressure then delivered to receiver
• The two stage compressor diagram shown in figure 4.
• In the two-stage air compressor with inter –cooler, the air is first taken into low pressure
cylinder, this air is compressed into the cylinder.
• Then air is passing to intercooler.
• The air is cooled at constant pressure to its original tempurater by cold water.
• When the air cooled to original temperature, the cooling perfect due to constant pressure
• The cooled air is passed to high pressure cylinder.
• For second stage, the H.P cylinder

figure 4 Actual indicator diagram for a reciprocating compressor:

 Figure 4 Actual indicator diagram

Compression:
Starting at maximum cylinder volume, point a, slightly below the inlet pressure p1, as the volume
decreases the pressure rises until it reaches p2 at b; the discharge valve does not open until the
pressure in the cylinder exceeds p2 by enough to overcome the valve spring force.
Compression, Adiabatic
The process in which no heat is transferred to or from the gas during the compression process.
Compression, Isothermal
Compression is which the temperature of the gas remains constant.
Compression, polytrophic
Compression in which the relationship between the pressure and the volume is expressed by the
equation PVn is a constant.
1.4.7 Rotary Compressor
Rotary compressors have rotors in place of pistons and give a continuous, pulsation free discharge
air. They are directly coupled to the prime mover and require lower starting torque as compared to
reciprocating machine. They operate at high speed and generally provide higher throughput than
reciprocating compressors.
Rotary compressors having positive displacement may be of following types:
• Roots blower
• Screw type or helical type compressor
• Vane type compressor
Roots blower:
Roots blower is a positive displacement type rotary compressor. It has two rotors having two or
three lobes having epicycloid and hypocycloid or involute profiles such that they remain in proper
contact. Figure below shows two lobe rotors in a root

Figure 5 Figure 6 Roots blower

Vane type compressor:
The rotary sliding vane compressor consists of avane-type rotor mounted eccentrically in a
housing. As the rotor turns, the vanes slide out against the housing. Air compression occurs when
the volume of the spaces between the sliding vanes is reduced as the rotor turns in the eccentric
cylinder. Single or multi-stage versions are available. This type of compressor may or may not be
oil lubricated. Oil-free rotary sliding vane compressors are restricted to low-pressure applications
because of high operating temperatures and sealing difficulties.

Figure8 Vane type compressor

2.5.8Volumetric efficiency:
The volumetric efficiency, ηVis defined as the ratio of actual volumetric flow rate of air to the
maximum possible volumetric flow rate, which is equal to the compressor displacement rate.

2.5.9 Clearance Volume:

The maximum cylinder volume on the working side of the piston subtracts the displacement
volume per stroke. Normally it is expressed as a percentage of the displacement volume.
2.5.10 Isothermal efficiency (ηt):
Isothermal efficiency is defined by the ratio of isothermal work and actual indicated work in
reciprocating compressor.

2.5.11 Intercooler:
Intercooler" meaning "between" cooler.Intercoolers are used to cool the charge intake air after it
has been compressed by the turbo(s). By using an intercooler, that air can be brought to a
temperature where it will not do so. Also, the cooler the air, the more air can enter the chamber
and produce power.
Data:
Low pressure cylinder
D= 95mm
L= 50mm
High pressure cylinder
D= 50mm
L=50mm
Swept volume/rev =0.384×10-3
Cpwater = 4.18 kj/kg k
Air flow measurement Q = 4.71384×10-5√ℎ × (𝑡1 + 273)
T1 = 1st stage inlet
T2= 1st stage outlet
T3 = 2nd stage inlet
T4 = 2nd stage outlet
T5 = water inlet
T6 = water outlet
Observations&specimen calculations:
Reading no. 02
T1 = 260C
T2 = 103.10C
T3 = 40.90C
T4 = 52.40C
T5 = 34.40C
T6 = 32.60C
1st stage pressure = 220 KNm-2
2nd stage pressure = 200 KNm-2
Manometric height= 81 m
Motor volts = 370V
Compressor speed = 1330 rpm
Compressor current = 6.5 A
Calculation
Inlet abs =Pia = Pi + Patm = 0 + 101.325 = 101.325 KNm-2
1st stage abs= Pia = P1 + Patm = 220 + 101.325 = 321.325 KNm-2
2nd stage abs = P2a =P2 + Patm = 200 + 101.325 = 301.325 KNm-2
𝑃1𝑎 321.325
1st stage pressure ratio = 𝑃𝑖𝑎 = 101.325 = 3.17
𝑃2𝑎 301.325
2nd stage pressure ratio = 𝑃1𝑎 = 321.325 = 0.93
𝑃2𝑎 301.325
Overall pressure ratio = 𝑃𝑖𝑎 = 101.325 = 2.96

Table 2.1

Sr.# T1 T2 T3 T4 T5 T6 H P1 O2 I V N
01 26 73 31.3 34.3 29.5 30 81 200 100 6.5 370 1330
02 26 103.1 40.9 52.4 34.4 32.6 81 220 200 6.5 370 1330
03 21.1 112.3 46 63 6.1 34.8 79 240 300 6.5 370 1330
04 21.9 119.4 44.9 80.1 31.5 41.8 76 260 400 6.5 370 1330
05 28 128.9 53.1 91.8 38.6 4.3 76 260 500 6.8 380 1321
06 28.5 133.5 56.1 102.7 39.1 44.1 76 260 600 6.7 380 1310
07 28.9 137.6 58 113.2 39.4 44.7 76 280 700 6.7 380 1310
08 29 1140.7 59 118.6 39.6 45 76 280 800 6.7 380 1300
 Sr.# Q×10-3 P/R 1st P/R 2nd Overall P/R
01 7.6 2.98 0.66 1.98
02 7.36 3.17 0.93 2.96
03 7.21 3.37 1.17 3.94
04 7.15 3.57 1.66 5.90
05 7.10 3.57 1.94 6.88
06 7.05 3.77 2.10 7.86
07 7 3.77 2.36 8.84

Graph between Q,1st stage P/R, 2nd stage P/R and Overall P/R
7.7

7.6

7.5

7.4
1st stage
7.3
2nd stage
7.2 overall
7.1

6.9
0 2 4 6 8 10

Comments:
• The cycle’s performance is too close to its optimum point in winter season. With a large
increase in the ambient temperature (in summer), the cycle keeps away from optimum point.
Total power of the cycle reduces in the range of 2.9%–9.6% by this optimization method in
winter and summer conditions, respectively.
• To optimize total work of the cycle and to supply the required pressure ratio in the hot region,
speed of compressors should be independent from each other. Consequently, compressor
designing for a hot climate should be in the form of split shaft (especially the first-stage
compressor) for operating compressors in different speeds and thus different pressure ratios to
save more energy.
• To determine pressure ratios, one should consider intercooler performance. In winter season,
pressure ratio of the first compressor should be larger than the other compressor (and vice versa
in summer season), because in this condition, the inlet air temperature to the first compressor
is smaller than that of the second compressor.
1.10 Applications
Air compressor machines are used for several different applications.
Small oil-free air compressors can be used for brush paintings, medium sized air compressors up
to 50 liters are normally used for spray painting & bigger capacity compressors are used for several
pneumatic applications in workshops & industries.