MODULE 1

LEARNING OUTCOMES:
1. Define Air Compressor
2. Know the Types and parts
3. Explain the principle of operation of single stage reciprocating air compressor
4. Draw and interpret the processes on the PV diagram.
5. Analyze the three Works of compression and Piston displacement
6. Calculate the Capacity, Pressure, Volume and Temperature relationships
7. Show the Volumetric and Compressor efficiencies.
8. Illustrate the PV diagrams of 2-stage, 3- stage Reciprocating compressors with
and without clearance
9. Solve the Intermediate pressure
10.Analyze the work of compression, Piston Displacement and capacity.

COMPRESSORS
Are machines that are used to transfer gasses from one location to another at a higher
differential pressure ranges. There are various types of compressors and are classified
in two major categories:
1. Dynamic or continuous flow- are types of compressors in which the flow of gas is
accelerated thru high speed rotating element, converting velocity head into pressure
head. It includes centrifugal and axial flow compressors
2. Positive displacement or intermittent flow types of compressor – are those units
that confine gas in a closed space, reducing its volume and discharging it at a higher
pressure. Intermittent flow includes, reciprocating, screw, and roots types of
compressors.

SOME OTHER WAYS OF CLASSIFYING COMPRESSORS

a. Number of stages
b. Reciprocating compressor element: single acting or double acting
c. Cylinder arrangement: vertical, horizontal, V-type
d. Cooling system: Water cooled or air cooled
e. Mounting condition: portable or stationary
Are positive displacement, intermittent-flow machines that are capable of delivering air from
a pressure of 35 psig up to 250 psig. They are widely used in industrial applications because of
their overall efficiency, wide range of capacity simplicity of use and compactness

TYPICAL COMPRESSOR WITH ITS PARTS

OTHER TYPES OF GAS COMPRESSORS:

a. Centrifugal compressor for super charger – Exhaust gases from Diesel
engine ( at some 1200 0F) expand through the nozzle passages, pass through
the turbine wheel, and produce the work to drive the centrifugal
compressor. With a greater mass of compressed air in the cylinder, the
power output maybe increased some 50% for a given size cylinder.

b. Two stage, Air cooled compressor – It has a high and low pressure cylinders
with finned air intercooler. Sometimes recommended for a discharge
pressure as low as 80 psia.

c. Diffuser and impeller – This actually one stage of a centrifugal pump, but
the stage in a multi-stage blower or compressor would look much the same.

d. Two – stage water cooled compressor –With high and low pressure
cylinders where the intercooler is cooled by water.
e. Positive Displacement Blower – Gas trapped between lobes and enclosing
surface on the intake side, is compressed and delivered to the discharge
side. This idea is also used as with liquid pump.
f. Sliding – Blade Compressor – The rotor is mounted eccentric to the casing,
gas entering on the side of the greatest clearance is kept between the
blades, compressed, and delivered from the side with minimum clearance

COMPRESSOR SELECTION
The following are important items to consider in selecting a compressor:
a. Desired capacity, V1’
b. Required discharge pressure
c. Characteristics of the gas handled
d. Type of control required

COMPRESSOR INSTALLATION

The following are some of the guidelines and precautions in installing a compressor:
a. It is necessary to have a good foundation for the compressor unit in order to
stabilize the vibration that occurs during operation.
b. Inlet filter should be installed in the suction of the compressor to protect the
unit from dust, foreign object, moisture and corrosive elements present that
may damage the compressor.
c. To reduce friction and turbulence, all compressed air piping system lines
should be short and straight as possible, with minimum elbows, valves and
fittings.
d. d. One of the challenges to maintain compressed air piping system is the
collection of water in the pipelines. A suitable water drain or collector should
be available at each point in the line.
e. e. Install a compressor in a secure location and at the same time, available for
inspection and maintenance.
f. f. Silencers may be used if noise level is primary consideration.
AIR RECIEVERS
• It is necessary for all reciprocating compressor to have an air receiver to
eliminate the pulsation of air delivered. It is also used to store compressed air,
and to condense some of its moisture content by cooling it down.
VT = V1’P1 / P2 Where: V1’ = Actual capacity
P1 = Suction pressure of the compressor

Air receiver size depends on the capacity of the compressor, pipeline network and
pressure drop, air consumption of the plant and switching cycle per unit-time of the
compressor operation.

RECIPROCATING COMPRESSOR WITH THE PV- DIAGRAM

Compression stroke starts at point 1, as the compressor compress the air
from point 1 to point 2, the suction valves immediately immediately closed, shutting
off the suction line of the cylinder. At point 2, the discharge valve opens and
compressed air is pushed out of the cylinder into the discharge line of the cylinder.
The discharge stroke is completed at point 3. At this point, the piston
returns to point 4, where the pressure drops and closing the discharge valve. The
clearance between the end of the cylinder and the Top Dead Center (TDC), is known
as the “clearance” volume.
The piston expands to from point 3 to 4, and the intake stoke occurs from
point 4 to 1, which also known as the “compressor capacity”. The complete cycle is
known as the PV diagram.
WORK OF COMPRESSION

FUNDAMENTALS OF COMPRESSOR:
1. Work of Compressor, Wc

a. Work for Polytropic Compression, PVn= C

nP ₁V ₁'
Wc = ⦋ ¿ )n-1/n-1]
n−1
b. Work for Isentropic Compression, PVk = C

kP ₁V ₁ '
Wc = ⦋ ¿ )k-1/k-1]
k −1
c. Work for Isothermal Compression, PV = C

P₂
Wc = P1 V1’ ln ( )
P₁
2. Compressor Capacity, V1’
- it is the actual volume of air drawn in by the compressor as measured
at the intake pressure and temperature

V 1 ’ = V 1 – V4

V1 =( maRT1)/P1

Where: R = ideal gas constant

= 0.287 KJ/kg-K for air
ma = mass of actual air drawn in by the compressor
T1 = absolute temperature of gas at the start of compression
P1 = absolute pressure at start of compression

3. Pressure, Volume and Temperature relationships

T₂
T₁
= ( Pp ₂₁ )n-1/n = ( VV ₁₂ )n-1
Where: 1˂ n ˂ 1.4 for Polytropic compression
n = k = 1.4 for Isentropic compression
n = 1 for Isothermal compression

4. Volumetric efficiency, nv

= (actual volume/ volume displacement) x 100%

nv = ( V1’/VD ) x 100%
= 1+c – c (P2/P1)1/n x 100%
Where: c = percent clearance ranges from 3 to 10%
P2 = discharge pressure
P1 = suction pressure
5. Compressor efficiency, nc
- The ratio of compressor power output over the brake power input to
the compressor

nc = (Work of the compressor(Wc)/Brake power ) x 100%

TWO STAGE COMPRESSOR

Air enters at point 1, compresses to point 2 by the low pressure cylinder (LPC),
passes through an intercooler to cool the air using water ( Indirect contact) before
it enters the high pressure cylinder (HPC), final compression till point 4.

The cycle is shown in the PV Diagram:

The savings in power is the area shaded with red color. If you compress the air
to point 4 with only one cylinder, then the PV diagram is from 1 to 2 up to the dotted
lines. But if 2-stage of compression, the flow is from 1 to 2 then cooled back to 3
before compressing it to point 4 using a high pressure cylinder. The difference in the
enclosed area is known as power savings.
1. Compressor work :
W = nP1V1’ /n-1⦋ (P2/P1)n/n-1 - 1] + nP3V3/n-1⦋ (P4/P3)n/n-1 - 1]

= n mRT1/ n-1⦋ (P2/P1)n/n-1 - 1] + nmRT3 n-1⦋ (P4/P3)n/n-1 - 1]

T1 = T3 ( Perfect intercooling)

Px = P2 = P3

Px = (P1P4)1/2 ( Intercooler pressure)

W =2 nP1V1 /n-1⦋ (P2/P1)n/n-1 - 1] = 2n mRT1/ n-1⦋ (P2/P1)n/n-1 - 1]

2. Heat rejected in the intercooler

Q = mCp ( T2 – T3 )

Where: m = actual mass of air entering the compressor

Cp = specific heat of air
= 1.0 kj/kg –K

3. Heat absorbed by cooling water

Q = mwCpw ( Tout – Tin)

Where : mw = mass of cooling water

Cp = specific heat of cooling water
= 4.187 kj/kg – K

TWO STAGE COMPRESSOR WITH PRESSURE DROP IN THE

INTERCOOLER

PV DIAGRAM
In the PV diagram, when cooling the air in the intercooler, there is a pressure
drop. It has to be considered in the calculation

THREE – STAGE COMPRESSOR

In the three-stage compression, the air is compressed from 1-2 by the low pressure
cylinder, cooled back to point 3 using an intercooler, compressed to point 4 by the
intermediate cylinder, cooled back to 5 and finally compressed to point 6 by the High
pressure cylinder.
Higher pressure will be attained if the compression is Multi –Stage.
1. INTERCOOLER PRESSURE

Px = P2 = P3
PY = P 4 = P 5
Px = ⦋(P1 ) 2 P6 ]1/3
Py = ⦋ P1(P6)2 ]1/3

2. HEAT REJECTED IN THE INTERCOOLERS

Q = 2 mCp ( TH2O out – TH2O in)

EXAMPLES:

1. A single stage air compressor handles 0.454 m3/sec of atmospheric pressure,

270C air, and delivers it to a receiver at 652.75 Kpa. Its volumetric
efficiency is 0.72, its compression efficiency on an isothermal basis is 0.85
and its mechanical efficiency is 0.90. If it rotates at 350 rpm, what power in
KW is required to drive it?

Solution:
Drive power = Wc /nc nm
Where: Wc = Work of compression ( Isothermal work as given in the
problem)
nc = compression efficiency
nm = mechanical efficiency
P₂
Wc = P1V1’ ln ( )
P₁
652.752
= 101.325kn/m2 (0.454 m3/sec) ln )
101.325
= 85. 694 Kw
Thus,
85.694
Drive power =
0.85(0.90)
= 112.02 Kw

2. Air taken from the atmosphere at 100 kpa and 21 oC is delivered to the air
receiver at 690 kpa and 150 oC by means of water jacketed reciprocating
compressor. The compressor has a rated capacity of 0.15 m3/sec free air.
Determine the power required to compress the air.

Solution:
nP ₁V ₁'
Wc = ⦋ ¿ )n-1/n-1]
n−1
Where:
P1 = 100 kpa
P2 = 690 kpa
V1’ = 0.15 m3/sec

Solving for n:

T₂ P ₂ n-1/n
=( ¿
T₁ P₁

(150+273) 690 n-1/n

=( ¿
(21+273) 100

n = 1.232
Then;

(1.232)(100)(0.15) 985.6 1.232-1/1.232

Wc = ( ( 98.56 ) - 1)
1.232−1

= 34.94

PAST ME BOARD PROBLEMS:

1. A two stage compressor with first stage piston displacement of 94,390 cm 3/sec
is driven by a motor. Motor output is 35 Hp, suction temperature is 22 oC,
volumetric efficiency is 85%, mechanical efficiency is 95%, the intercooler
pressure is 30 psi gage. Air temperature in and out of the intercooler are 105 oC
and 44oC. Final discharge pressure is 100 psi gage, suction estimated at 14.5
psi. Find the compression efficiency.

Solution: Let nc= compression efficiency

nm= mechanical efficiency
nc= Total work of compressor/(motor ouput)(nm)
Convert the pressures in kpa;
101.325
P1 = 14.5( ) = 99.946 Kpa
14.7
101.325
P2 = (100 +14.7)( ) = 790.611 Kpa
14.7
101.325
P3 = (30 +14.7)( ) = 308.111 Kpa
14.7

Solving for m;
P1V1’ = mRT1
nv = Actual volume drawn in( V1”)/ Piston displacement( VD)
V1’ = ( 0.09439)(0.85) = 0.0802
99.946(0.0802) = m(0.287)(22+273)
m = 0.0947 kg/sec

Solving for n;
T₂ P ₂ n-1/n
=( ¿
T₁ P₁

(105+273) 308.111 n-1/n

(22+273)
=( 99.946
¿

n = 1.2824

then; Work of LPC ( 1st stage)

WLPC =nmRT1 (( P2/P1)n-1/n – 1)
WLPC = 10.245 Kw
P ₄ n-1/n
WHPC = nmRT3( ( ) -1)
P₃
= 9.024 kw
Total work of the compressor = 19.269 Kw
Note: if there is no way to solve for the work of HPC then assume W LPC be equal to
the WHPC
Thus;
19.269
nc = kw = 0.7768
35(0.746 )(0.95)
hp
=0 .7768( 100%)
= 77.68%

2. An air compressor is to compress 8.5 m3/min from 98.56 Kpa to 985.6 Kpa,
assuming conditions ideal, and with n=1.3, what would be the saving in work due to
two staging?
Solution:
For single stage compressor;
nP ₁V ₁'
Wc = ⦋ ¿ )n-1/n-1]
n−1
(1.3)(98.56)(8.5 /60) 985.6 1.3-1/1.3
= (( ) - 1)
1.3−1 98.56
= 42. 43 KW

For two stage compressor;

PX =√2 P₁ P ₂

PX = √2 98.56 ( 985.6 )

= 311.67 Kpa

nP ₁ V ₁ '
Wc = 2 ⦋ ¿ )n-1/n-1]
n−1
2(1.3)(98.56)(8.5/60) 311.67 1.3-1/1.3
= (( ) - 1)
1.3−1 98.56

= 36.83 Kw
Power saved = 42.43 – 36. 83 = 5.6 KW