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RECIPROCATING COMPRESSORS
4.1 Introduction
4.2 Working Cycle & p-v Diagram
4.3 Indicated Power and Work
4.4 Conditions for Minimum Work
4.5 Mechanical Efficiency
4.6 Isothermal Efficiency
4.7 Clearance Volume
4.8 Volumetric Efficiency
4.9 Multistage Compressor
1
4.1 INTRODUCTION
2
Basic Components of a Reciprocating
Compressor Outlet Inlet
3
1. Air intake, 8. Pressure gauge,
2. Compressor pump, 9. Manifold,
3.Outlet, 10. Regulator,
4. Drive belt, 11. Supply line,
5. Motor, 12. Air tank,
6. Control switch, 13. Water drain,
7. Relief valve,
4
4.2 WORKING CYCLE & THE p-V DIAGRAM
(d – a): Induction (intake) Delivery
Induction valve opens
valve
Air is induced into the cylinder
Volume and mass increases
Pressure and temperature is constant Induction
during this process valve
(a – b): Compression v2 v1
Inlet valve closes p
Piston compresses air
Pressure rises until P2 at (b)
c b
p2
Temperature also increases
(b – c): Delivery
Delivery valve opens
5
4.3 WORK & INDICATED POWER
The work done on air for one cycle is the area in the graph (area abcd)
Considering a polytropic process which follows the gas law PVn =
constant
p
Work for polytropic process is given by:
p v p1v 1 P2 c b
Win 2 2
1 n
where
n polytropic index of a gas
P1 d a
V
0 e f
6
Work input per cycle p
7
EXAMPLE 4.1
A single stage reciprocating compressor operates by inducing
1m3/min of air at 1.013 bar and 15oC and delivers it at 7bar.
Assume the compression process being polytropic and the
polytropic index is 1.35. Calculate:
i. Mass of air delivered per minute
ii. Indicated power
SOLUTION
pV
so m
RT
m
1.013 100 1 kg
1.23
0.287 15 273 min
8
n
ii. Indicated power can be determine using formula IP m R T 2 T 1
n 1
n 1
1.35 1.23
• Indicated power; IP 0.287475.4 288
1.35 1 60
7 2
1.013 1
V
0
9
4.4 CONDITIONS FOR MINIMUM WORK
We know that the work done is equal to the area under the graph
The smaller the area the lesser the work and the better the
compressor
For reciprocating compressors, the pressure ratio is fixed, so the
height of p-v diagram is fixed
The volume of cylinder is also fixed so the line d-a is fixed
Therefore the area representing work depends the index n.
For n = 1,
pV = constant (Isothermal)
For n = ,
pV = constant (isentropic)
So, the process can be polytropic, isothermal or isentropic
10
pV =constant (isothermal) p
b1 b b2
pV =constant (isentropic) P2 c
pVn =constant (polytropic) pV = C
pVn = C
pV = C
From here it can be seen
that the isothermal process
is the best because it P1 d a
requires minimum work
0 e f
v2 v1 V
So it is best that the gas
temperature is constant
throughout the compression
cycle
11
ISOTHERMAL WORK
p2Vb1 ln
p1
p1Vb1 p1Va p
p2 b1
for isothermal process p1Va p2Vb P2 c
p2 p2
Win p2Vb1 ln p1Va ln pV = C
p1 p1
From pV mRT
p
Win mRT ln 2
p1
P1 d a
where T is the constant t emperature
p
Isothermal power m RT ln 2 0 e f
p1 V
12
4.6 ISOTHERMAL EFFICIENCY
Isothermal efficiency indicates isothermal work compared to the
indicated work.
Isothermal Work
Isothermal Efficiency ,isoth
Indicated Work
EXAMPLE 4.2
A single stage reciprocating compressor induce 1.23kg/min
of air at pressure 1.023 bar and temperature 23oC and
delivers it at 8.5 bar. If its polytropic index is 1.3,
determine:
i. Indicated power
ii. Isothermal power
iii. Isothermal efficiency
13
SOLUTION
kg
We know: m 1.23 , P1 1.023bar @ 102.3kPa
min
T1 23o C @ 296K and P2 8.5bar @ 850kPa
n
i. Indicated power can be determine using IP m R T 2 T 1
n 1
n 1
0.287482.5 296
1.3 1.23
• Indicated power; IP
1.3 1 60
14
p2
ii. Isothermal power can be determine using W
isothermal m RT ln
p1
1.23 850
W isothermal 0.287 296 ln 3.68kW
60 102.3
isothermal power
iii. Isothermal efficiency can be determine using isoth
indicated power
Wisothermal 3.68
isoth 0.78 @ 78%
IP 4.75
15
4.5 MECHANICAL EFFICIENCY, ηm
Because there are moving mechanical parts in the compressor, it is
likely that losses will occur due to friction
Therefore power required to drive the compressor is actually more
higher than the indicated power
So there is need to measure the mechanical efficiency of the cycle
Mechanical efficiency of the compressor is given by:
indicated power
m required power
16
• If Indicated power IP = 4.5 kW and mechanical efficiency, m is 0.8
the shaft power would be:
4.5kW
Shaft power 5.625kW
0.8
17
4.7 CLEARANCE VOLUME (VC)
In actual compressors, piston does not reach the top of wall of the
cylinder.
Instead it reaches maximum stroke at a certain distance from the wall.
The remaining volume of the cylinder where piston does not travel
through is call the clearance volume VC.
The volume where the piston does travel through is called the swept
volume, VS.
Purpose – to give freedom for working parts and space for valve
operations
18
Process P
19
Effect of VC
P
Because of the expansion of
e c b
gas remaining in the VC, p2
induced volume is reduced from PVn = C
swept volume VS to (Va – Vd)
PVn = C
which is the effective volume
V Va Vd or V Va Vd p1
f d a
Mass or air per unit time
VC VS v
m a m b and m c m d
20
INDICATED WORK & INDICATED POWER FOR
COMPRESSOR WITH CLEARANCE VOLUME
Work done per cycle
W area abcd area abef - area cefd
cycle
n n
Indicated power W m a R T 2 T 1 m d R T 2 T 1
n 1 n 1
n
m a m d R T 2 T1
n 1 P
e c b
because m a m d m mass induced per unit time p2
n 1
PVn = C
n n p n
W mR T 2 T 1 mRT 1 2 1
n 1 n 1 p 1 PVn = C
kg
where m N m
min p1
f d a
kg
or m N ma md
min
VC VS v
21
Double-acting Compressors
A single-acting compressor completes one compression cycle with one revolution of
the crank
A double-acting compressor completes two compression cycles with one revolution
of the crank
So the mass induce per revolution is twice than a single acting where
kg kg
m 2 N m or m 2 N ma md
min min
Delivery Delivery
Induction Induction
22
EXAMPLE 4.3
A single stage, double-acting compressor is required to deliver 8m3/min of
air measured at pressure of 1.013 bar and 15oC. Delivery pressure is 6 bar
and crank speed is 300rpm. The clearance volume is 5% of swept volume
and the compression index is 1.3. Calculate
i. Swept volume, VS
ii. Delivery temperature, T2
iii. Indicated power
23
SOLUTION
We know: T1 15o C @ 288K and P1 1.013bar ; P2 6bar and N 300rpm
Since it is double acting, per minute, it will P
have 300 x 2 = 600 cycle that induces 8 c b
m3. It means for one cycle it will induce; 6
PV1.3 = C
8
V a V d 0.0133m 3
600 PV1.3 = C
Vs Va Vc
Vs Va 0.05Vs
Va 1.05Vs (1)
24
P
• From polytropic equation P1Vd n P2Vc n c b
1 1
P2
n
6 1.3
Vd Vc 0.05V s
PV1.3 = C
P1 1.013
PV1.3 = C
Vd 0.196Vs (2)
n 1
T 2 P2 n
ii. Delivery temperature, T2 can be determine using
T 1 P1
1.3 1
6 1.3
T 2 288 434.6K or 161.6o C
1.013
25
n
iii. Indicated power can be determine using IP m R T 2 T 1
n 1
m 3
NOTE: we can straight away obtain m using the value of V 8
min
P1V 1.013 100 8 9.8 kg
m
RT1 0.287 288 min
n
1.3 9.78
IP m R T 2 T 1 0.287 434.2 288
n 1 1.3 1 60
IP 29.64kW
26
4.5 VOLUMETRIC EFFICIENCY, ηv
Volumetric efficiency is another definition to measure the
performance of a compressor.
The are two ways how to define volumetric efficiency:
st
1 definition:
27
P
So by first definition, e c b
p2
V Vd P1 T 0
p1
f d a
v a
Vs P0 T1
V Vd VC VS v
If assume P1 Po and T1 To , v a
Vs
V s Vc V d V s Vc V d
v
Vs Vs Vs Vs
V V V V
v 1 c 1 d 1 c d 1 (1)
Vs Vc Vs Vc
28
n n
Since P1Vd P2Vc
1
n
Vd P Vd P2 n
2 and therefore
Vc P1 Vc P1
29
VOLUMETRIC EFFICIENCY, ηv
2nd definition:
The ratio of the actual volume (Vactual) in the cylinder that is
measured at free air condition with swept volume (Vs)
30
Combining the two mathematical definition, we get
v
Va Vd P1 T 0
Vs P0 T1
Note that the equation above is the same the one in the first
definition.
31
FREE AIR DELIVERY (FAD)
32
EXAMPLE 4.4
A single stage, single-acting compressor delivers 3m3/min of air measured
at pressure of 1.014bar and 23oC. During induction, pressure and
temperature or air is 0.98 bar and 43oC respectively. Delivery pressure is
6.5 bar and crank speed is 358 rpm. The clearance volume is 5% of swept
volume and the compression index is 1.3. Calculate
i. Indicated power
ii. Volumetric efficiency
33
P
SOLUTION
c b
6.5
We know:
T 0 23o C @ 296K and P0 1.014bar @ 101.4kPa PV1.3 = C
T1 43o C @ 316K and P1 0.98bar @ 98kPa
PV1.3 = C
FAD 3 m
3
, N 358 rpm and P2 6.5bar @ 650 kPa
min
34
n
1.3 3.58
IP m R T 2 T 1 0.287489 316 12.84kW
n 1 1.3 1 60
Vactual @ FAD
ii. Volumetric efficiency can be determine using v
Vs
We know: m P1 Va Vd
and m 3.58
kg
, FAD 3 m
3
RT 1 min min
3.31
Since N = 358 rpm, Va Vd 0.00925m 3
358 P
c b
From the diagram
Vs Va Vc
Vs Va 0.05Vs
Va 1.05Vs (1)
d a
VC VS v
35
P
• From polytropic equation P1Vd n P2Vc n c b
P2
1 1
P2 n
6.5 1.3
Vd Vc 0.05Vs
P
1 0.98
Vd 0.214Vs (2)
P1
d a
Insert (1) and (2) in equation Va Vd 0.00925m
3
•
v
1.05 0.214Vs 0.00925m 3 VC VS
V s 0.011m 3 or 11 litre
min
Vactual @ FAD
3.31
0.84 @ 84%
v
V s 3.938
36
4.6 MULTI-STAGING COMPRESSOR
• When delivery pressure is P
increased to a higher value, p4 c” b”
several weaknesses were
found:
p3 c’ b’
1. Induce volume will become
lesser
2. Increase in delivery
temperature p2 c b
3. Decrease of volumetric
efficiency (FAD becomes lesser
were else no change in Vs) p1
d d’ d” a
37
Coolant in Coolant out
Intercooler
LP HP Compressor
Compressor
It consist of more than one compressor where the air passes through
an intercooler before entering the next compressor.
The size of the next compressor is smaller to compromise Vs.
In the intercooler, heat is transferred to the surrounding and
temperature will decreased. It will be brought back to its inlet
temperature (before induction process).
It is assumed that all compressors will have the same polytropic
index.
38
p
Advantages:
LP CPMPRESSOR
***NOTES:
a. Since no mass is allow to escape during its travel, mLP = mHP
b. If pressure ratio and the ratio of Vc/Vs is the same, volumetric efficiency
for both compressor is the same.
39
EXAMPLE 4.5
In a single acting, two-stage reciprocating air compressor, 4.5 kg/min of air is
compressed from 1.013 bar and 15oC surrounding conditions through a
pressure ratio of 9 to 1. Both stages have the same pressure ratio, and the
law of compression and expansion in both stages is PV1.3=C. The clearance
volume of both stages are 5% of their respective swept volumes and it runs
at 300 rpm. If inter cooling is complete, calculate:
i. Indicated power
ii. Volumetric efficiency
iii. Cylinder swept volumes required.
iv. Shows the power saving on p -v diagram and get the value in
percentage.
40
SOLUTION p(bar)
g f
P2
We know: HP
kg COMPRESSOR
m 4.5 , N 300rpm,T1 288K and n 1.3
min
P2 P P
9 , 2 i and T 1 T e c h e b
P1 Pi P1 Pi
LP COMPRESSOR
Pi
9 3
P1
n
IPLP m R T i T 1
n 1
41
n 1
p(bar)
T i Pi n
g
T 1 P1
P2 f
HP
1.3 1
T i 2883 371K COMPRESSOR
1.3
n
IPLP m R T i T 1 c
n 1
h e b
Pi
1.3 4.5
IPLP 0.287371 288 7.74kW
1.3 1 60 LP COMPRESSOR
n
IPHP m R T 2 T e and T e T1 1.013 a
n 1 d
n 1 V
T 2 P2 n Vc Vs
T e Pi
1.3 1
T i 2883 1.3 371K
n 1.3 4.5
IPHP m R T 2 T e 0.287371 288 7.74kW
n 1 1.3 1 60
42
p(bar)
ii. Since pressure ratio for and the ratio of
g f
P2
Vc:Vs is the same for both stages,
v LP v HP HP
COMPRESSOR
v
V Vd P1 T 0
a
V Vd
a
LP COMPRESSOR
Vs P0 T1 Vs
1.013 a
d
We know
V
m m 4 .5 Vc Vs
0.015kg
cycle N 300
43
From the diagram p(bar)
g f
P2
Vs Va Vc
Vs Va 0.05Vc HP
COMPRESSOR
Va 1.05Vs (1)
c h e b
Pi
n n
From polytropic equation P1Vd PiVc
1 LP COMPRESSOR
Pi
n 1
Vd Vc 0.05V s 3
1.3
P
1
1.013 a
d
Vd 0.1164Vs (2)
V
Vc Vs
v
Va Vd 0.01224
0.94 or 94%
Vs 0.013
44
p(bar)
iii. We already calculated Vs for LP
g f
P2
compressor. Since volumetric efficiency
for both stages is the same
HP
COMPRESSOR
v
Ve V h
0.94
Vs Pi
c h e b
Te T1
Pi 3.039 100
V
Vc Vs
0.00408m 3
Vs
Ve V h
0.00408
0.00434m 3 or 4.34litres
v 0.94
***NOTES:
Easier steps are shown in McConkey page 399-400
45
IDEAL INTERMEDIATE PRESSURE
The value chosen for the intermediate pressure pi influences the work
to be done on the air and its distribution between the stages.
Minimum power happen when dW 0 p(bar)
dPi g f
n 1
n 1
P2
n P n
n P n
W m RT 1 i 1 m RT e 2 1 HP
COMPRESSOR
n 1 P1 n 1 Pi
We know T e T 1
c h e b
Pi
n 1 n 1
LP COMPRESSOR
n P n P n
W m RT 1 i 2 2
n 1 P1 Pi 1.013
d
a
V
Vc Vs
dW n 1
2nn1
P1P2 Pi
n 0
dPi
46
n 1
2nn1
P1P2 n Pi
P1P2 Pi 2
or
Pi P2
P1 Pi
(pressure ratio is the same for each stage)
47
EXAMPLE 4.6
A three stage, single acting compressor running in an atmosphere at 1.013
bar and 15oC has an FAD of 2.83 m3/min. The induced pressure and
temperature is 0.98 bar and 32oC respectively. The delivery pressure is 70
bar. Assuming complete intercooling, n =1.3 and that the machine is design
for minimum work, calculate the indicated power required.
SOLUTION
n 1
1.3 1
n P Zn
1.3 3.47 70 3 1.3
W Z m RT 1 1 3
2
0.287 288 1
n 1 P1 1.3 1 60 0.98
W 24.2kW
48