3 Two Stage Air Compressor Manual

Two Stage Air Compressor ME-TH-3810
Contents
1. INTRODUCTION........................................................................................................2
2. GENERAL DESCRIPTION........................................................................................3
3. TECHNICAL DATA...................................................................................................5
4. GENERAL REQUIREMENTS:..................................................................................6
5. THEORY......................................................................................................................7
6. PERFORMANCE INDEX:........................................................................................15
7. EXPERIMENTAL PROCEDURES:.........................................................................18
8. DATA SHEET............................................................................................................19
9. TEACHER’S GUIDE.................................................................................................20
Page | 1
1. INTRODUCTION
Compressors are machines for compressing air or gas. They are widely used in industrial
factories for various functions as in handling of material in powder or particle form
(cement, starch and seeds), automatic system control, pneumatic power tools, chemical
compression process (sulfuric acid, ammonia gas), refrigeration, gas turbine, etc.
Compressors may be classified into 4 major types, i.e.

1. Reciprocating type,
2. Rotary type,
3. Centrifugal type
4. Axial flow type.
1. The reciprocating compressor is suitable for work application that requires high
pressure but not so high flow rate.
2. The rotary compressor is used in similar application as the reciprocating type,

but it has distinct advantages in having much less vibration, wear and tear.
However the disadvantage is in its high pitch noise which may be corrected by
silencers.
3. The centrifugal compressor is suitable for work application that requires not so
high pressure but very high flow rate.
4. The axial flow compressor is similar to the centrifugal compressor but for less
pressure and more flow rate.
In this manual, only reciprocating air compressor for high pressure will be discussed as
it is being most widely used today.
Page | 2
2. GENERAL DESCRIPTION
The test set is for studying the two-stage reciprocating air compressor characteristics.
An industrial type compressor is driven via a v-belt by a motor dynamometer with an
inverter. Air cooling of the compressor is done by fins. The air receiver has a safety
valve, a drain valve and a discharge valve.
The unit is equipped with necessary measuring instruments and is on wheels.
1 2 14 3 4 5
6 7 8 9 10 11 12 13
Figure 1: Two-stage air compressor test set, air cooled
Page | 3
1. Inclined tube manometer

2. Rpm meter
3. Pressure gauge
4. Two stage compressor
5. Guard
6. Temperature indicator
7. Motor power analyzer
8. Orifice meter
9. Stilling tank
10. Storage tank
11. Water flow control valve
12. Rota meter
13. Motor
14. Intercooler
Figure 2: General arrangement diagram
Page | 4
3. TECHNICAL DATA
T1 = Ambient air temperature

T2 = 1st stage outlet temperature
T3 = 2nd stage inlet temperature
T4 = 2nd stage outlet temperature
T5 = Cooling water inlet temperature
T6 = Cooling water outlet temperature
p1 = Atmospheric pressure
p2 = 1st stage outlet pressure
p3 = 2nd stage outlet pressure
N1 = Motor speed
N2 = Compressor speed
3.1. Compressors:
Type: Air cooled, two stage
First stage: Single or Twin cylinders with

Bore = Diameter = 80mm each
Stroke = Displacement = 60mm each
Second stage: Single cylinder with

Bore = Diameter = 65mm
Stroke = Displacement = 60mm
Motor dynamometer: 3.7 kW.
3.2. Measuring instruments:
Speed: Speed sensors for motor and compressor with a selector switch, and an
indicator.
Torque: Spring balance and torque arm = 120mm
Pressure: Pressure gauges at first stage and second stage outlets.
Air flow: Inlet orifice plate with an air box and an inclined water manometer.
Air box inlet diameter = D = 98.5mm
Orifice diameter = d = 25mm
Temperature measurement: Air inlet and outlet of each stage and water inlet and
outlet of intercooler.
Page | 5
Typical Test:
Compressor characteristics e.g. volumetric efficiency, isothermal efficiency, brake

horsepower, pressure ratio, temperature ratio
4. GENERAL REQUIREMENTS:
Electricity: 440V 3Ph.

Water Supply: Laboratory Water Supply or Hydraulic bench
Note:
Since there are water vapors in ambient air so these also get compressed along with air
to get rid of this timely drain the storage tank from the drain valve supplied at the
bottom of tank.
Page | 6
5. THEORY
5.1. Air Compression
In the compression of air or gas, the relation between absolute pressure (P) and volume
(V) may be expressed as follow:
pVn = C 1
Where: C and n are constant.
The graphical presentation for the change of compression state from point 1 to point 2
according to equation (1), so-called p-V diagram may be shown as in figure 2 below.
Figure 3 p-V diagram of air compression from state (1) to state (2)
C = Constant, depending on the type of gas
n = Constant, depending on the process in which gas is compressed
If the gas is compressed at a constant temperature, n = 1 and the compression process
is called “isothermal process”.
If no heat is added to or removed from the air mass during the compression,
k = Cp/Cv
Where:
Cp = Specific heat of gas at constant pressure, (normally = 1.005 kJ/kg K)
Cv = Specific heat of gas at constant volume, (normally = 0.718 kJ/kg K),
And the process is called “isentropic” or “reversible adiabatic” process.
In actual practice, the compression process is neither Isothermal nor Isentropic but a
combination of both processes. This third process is called “polytropic” process.
Page | 7
5.2. Compression in Cylinder
Compression in cylinder with no clearance:

All reciprocating compressors actually have a small clearance at the top of the cylinder
to allow for valve movement both in the suction and discharge sides. But for simplifying
the analysis, we will begin initially with a case of cylinder without clearance. In most
cases, the compressor is double acting type, i.e. the compression process takes place in
both forward and backward strokes. However, for this analysis, a single acting operation
will be considered. If it is required to analyze the double acting operation, it could be
done in the same manner or it can be considered approximately as being twice of the
single acting operation as shown in figure 4.
(a) Double Acting (b) Single Acting

Figure 4 Double acting and single acting cylinder
Figure 5 p-V diagram for a cylinder with no clearance.
Figure 5 shows the working cycle of a reciprocating air compressor. The process from
the initial state (0) to the first state (1) is in a suction stage of the operation in which the
pressure is constant until the piston moves to the bottom dead center (state 1). The
piston then returns and compresses the gas in the compression process from state 1 to
state 2 at which point the discharge valve opens while the piston still moving ahead. The
piston pushes the gas out of the cylinder in the process when pressure remains constant
until the piston reaches state 3, which is the top dead center of the piston. The
discharge valve is then closed and the piston starts to reverse its direction while the
suction valve opens and the pressure drops from state 3 to state 0. The new cycle is
then repeated indefinitely. Work done throughout the complete cycle may be calculated
as follows:
Page | 8
1 2 3 0
W cycle =∫ pdV +∫ pdV +∫ pdV +∫ pdV
0 1 2 3
2
= p1 ( V 1−0 ) +∫ pdV + p 2 ( 0−V 2 ) + 0
1
2
W cycle =( p1 V 1 − p2 V 2 )+∫ pdV
1 2
From equations (1) and (2), and assuming polytropic process;
n−1
n p2
3
W sysle =
n−1
p1V1
p1 [( ) n −1
]
p1 = Atmospheric pressure
= 1.013 bar
If the compression is Isothermal process where n = 1, then equation (3) becomes:
p2
W cycle =− p1 V 1 1 n
()
p1
4
From equation (3) and (4) of the cycle 0-1-2-3, it can be seen that work done for the
isothermal process is less than the work done for the polytropic process (or as long as
the value of n is more than one).Error! Bookmark not defined.
Compression in cylinder with clearance (Figure 6A):
In actual practice, reciprocating air compressor always has a clearance in the cylinder.
This clearance is expressed as % of cylinder total displacement volume and it is referred
to as % clearance (% C).
V3
%C=
V 1−V 3 5
Where
V3 = Clearance Volume
V1-V3 = Swept
Page | 9
Normally, %C varies between 3 and 10%, depending on valve design.
Figure 6A p-V diagram
Figure 6B T-S diagram
1-2 = Polytropic compression, pVn = Constant

1-2’ = Isothermal compression,
1-2’’ = Isentropic compression,
Figure 6 p-V and T-S diagram of single air compression with clearance acting.
Page | 10
The p-V diagram of figure 6 (A) is similar to that of figure 5 with an exception of state 3
being at state 3′, where the piston begins to move backward and both discharge and
suction valves are still closed. Thus the compressed gas in the cylinder clearance space
expands, resulting in further work done to the piston until state 4 is reached and the
suction valve opens. The calculation for the total work done in a complete cycle is as
follows:
Wcycle = Work done in the compression process + Work done in the expansion process
n−1 m−1
p p
6
W cycle =
n
n−1 [( ) ]
p1 V 1 2
p1
n
−1 −
m
m−1
p4 V 4 3
p4 [( ) ]m
−1
Since p1 = p4 and p2 = p3, and the expansion work is very small in comparison with the
compression work. Thus it can be assumed that m = n causing only small discrepancy in
using equation (6).
The area 1 2 3’ 4’ = Compression work done
n−1
p
W cycle =
n
n−1 [( ) ]
p1 ( V 1−V 4 ) 2
p1
n
−1
7
The difference between equation (7) and equation (6) lies in the term V4 which volume
depends on the pressure p1 and the temperature T1 respectively.
5.3. Two-Stage Air Compression:
Normally if a gas is to be compressed to a high pressure (more than 3 bars), it would be

obvious that a two-stage compression will require less work done than a single stage
compression. Two-stage compression can be done by using either two compressors or a
single compressor with two cylinders connected in series with an intercooler between
the two cylinders to transfer heat out of the compressor. This cooling reduces the
temperature of the compressed air; hence the compression work done is also reduced.
Normally, the intercooler is air cooled finned tube. However, for education purpose, the
intercooler may be water cooled. In this case, the intercooler effect is more pronounced
than air cool.
Page | 11
Figure 7 Work diagram of two-stage air compressor with intercooler
The amount of heat that is created by the compression of gas in stage 1 and then
transferred to the cooling water in the intercooler can be determined from the water
flow rate and the temperature difference of water between the outlet and the inlet
sides. In actual operation, a certain amount of heat created by gas compression is also
transferred to surrounding air. Works done for both stages of compression are as
follows:
n−1
p
Stage 1
8
W 1 st =
n
n−1 [( ) ]
p 1 ( V 1−V 7) 2
p1
n
−1
n−1
p
Stage 2
W 1 st =
n
n−1 [( ) ]
p 2 ( V 3−V 6 ) 3
p2
n
−1
9
Page | 12
Figure 8 p-V diagrams for two-stage air compressor
Figure 9 T-S diagrams for two-stage air compressor – isothermal process
Area 1-2-6-7 = Compression work done, stage 1

Area 3’-4’-5-6’ = Compression work done, stage 2 without intercooler
Area 3-4-5-6’ = Compression work done, stage 2 with intercooler
Area 3’-4’-4-3 = Compression work done or heat from stage 1, transferred to the cooling
water of the intercooler or to ambient air.
Under steady state of the compression, the total work done W total is the combination of
W1st and W2nd of equations (8) and (9) as follows:
Page | 13
From pV = mRT we obtain,
n−1 n−1
p p
10
W total=
n
n−1
mRT 1 2
p1 [( ) ] n
−1 +
n
n−1
mRT 2 3
p2 [( ) ]
n
−1
And if the intercooler can work perfectly, T2 = T1
n−1 n−1
p p
11
W total=
n
n−1
mRT 1 2
p1 [( ) ( ) ]
n
+ 3
p2
n
−2
or
n−1 n−1
p p
12
W total=
n
n−1
mC P 2
p1 [( ) ] n
−1 +
n
n−1
mC P 3
p2 [( ) ]
n
−1
n−1 n−1
p p
=
n
n−1
mC P 2
p1 [( ) ( ) ]
n
+ 3
p2
n
−2
Where p1 = Atmospheric pressure, N/m2

p2 = Pressure after Stage 1, N/m2
p3 = Pressure after Stage 2, N/m2
T1 = Room temperature, K
T2 = Temperature after compression Stage 1, K
m = Mass rate of air flow, kg/s
Nm
R = Gas constant of air = 287 kgK
In case T1 = T3, Wtotal will depend on p2. Thus we can differentiate the equation (10) by p 2
and equate to 0 to determine p2 at optimum (Wtotal is minimum), i.e.
( p2 )opt =√ p 1 p 4 13
Page | 14
6. PERFORMANCE INDEX:
6.1. Electrical power (EP)

EP (in W) is the electrical power supplied to the motor to drive an air compressor.
EP = E×I×φ 14
Where
E = Voltage, Volts
I = Current, Ampere
φ = Power Factor
This electrical power may also be directly measured by a Wattmeter.
6.2. Brake power (BP) or shaft power
This is the power (in W) that the motor supplies to the compressor.
BP = Torque × ω
Or
2 πN Nm
F . r× =W
BP = 60 s 15
Where N = Motor speed,
r = Length of dynamometer torque arm, m

F = Turning force on torque arm, N
(1 kg = 9.807 N)
Thus
BP = 0.10476 FrN
16
6.3. Air mass flow rate
The air mass flow rate going into the compressor is calculated from the rate of flow
through the orifice of the inlet box and the differential pressure of the manometer as
follows:
2 Δp A2
Q=
√ ρ
∗
A2 2
Where Δp = pressure difference from manometer in inches

√ 1−(
A1
)
ρ = density of air
A 2 = dia of smaller orifice
Page | 15
A 1 = dia of larger orifice

As for the mass flow rate of the compressor outlet from the air receiver, it can be
calculated from the flow rate through the orifice and the differential pressure of the
manometers in the same manner as above. If the pressure in the air receiver is constant,
both flow rates (in and out of the compressor) will be equal. In normal practice, the
mass flow mass through the inlet box is basically used.
6.4. Isentropic power (Isen P)
This is the theoretical power from the theory of isentropic compression process
(reversible adiabatic process).
n−1 n−1
T p2 p3
. .
W=m R 1 {
( )
p1
n
} {
−1 +m RT 2 ( )
p2
n
−1
}
T = Temperature, K
p = Pressure, N/m2
Subscript 1 = Inlet
Subscript 2 = Outlet or discharge
.
m = Mass flow rate kg/s
R = General Gas constant
6.5. Isothermal power (Iso P)
This is the minimum horsepower for the compression process calculated as follows:
p2 p
IsoP=p 1 V 1 ln
( ) p1 ( )
+ p 3 V 3 ln 3
p2
18
But
p1V1 = p3V3 ∴
Iso P= p1V1 (ln p2 − ln p1 + ln p3 − ln p2)
= p1V1 (ln p3 − ln p1)
p3
p1 V 1 ln
= p1 19
Where,
p = Pressure,
V = Volume per unit time, m3/sec
Isentropic efficiency (Isen eff %)
By definition,
Page | 16
IsenP
100×
Isen eff % = BP 20
Page | 17
Isentropic efficiency (Isen eff %)

By definition,
IsoP
100×
Isen eff % = BP 21
System efficiency
By definition,
Sys Eff % = 100 x Isen P / BP 22
Volumetric efficiency
By definition,
Vol eff % = Flow capacity × 100

First stage displacement
= qv
Swept Volume × speed
Cycle
Where:
qv is volume flow rate (m3/s). The volume flow rate can be determined from
qm = qv . ρu 23
Page | 18
7. EXPERIMENTAL PROCEDURES:
 Start the compressor by pushing green button on control box. Slightly open the
air receiver discharge valve to maintain a constant pressure in the air receiver
tank.
Record the following data:
 Motor speed and compressor speed by turning the knob to the right and left
respectively.
 Note down Pressures after stage 1 and stage 2, in the receiver and after
the air receiver discharge valve
 Temperatures of ambient air, after stage 1, after stage 2, in the air
receiver and after receiver discharge valve
 Inclined manometer levels at the air tank inlet and the discharge pipe section.
(Before recording the level of the manometer water reservoir should be adjusted
to the mark level).
7.1. Calculations
From the recording data, the following calculations can be made:

1. Actual air flow rate ()
2. Swept volume, from the size of the cylinder and stroke of the piston in stage 1
and speed.
3. Brake horsepower (BP).
4. Isentropic horsepower (Isen. HP.
5. Isothermal horsepower (Iso. HP).
6. Isentropic Efficiency (Isen. Eff), isothermal efficiency (Iso Eff) and volumetric
efficiency (Vol Eff).
Page | 19
8. DATA SHEET
Item Test Test Test Test Test

No.1 No.2 No.3 No.4 No.5
Motor speed 1, rpm (N1)
Compressor speed 2, rpm (N2)
Spring balance reading, kg (F)
Ambient temperature (T1)
Stage 1 compressor outlet (T2)
Stage 2 compressor inlet (T3)
Stage 2 compressor outlet (T4)
Water inlet (T5)
Water outlet (T6)
Air box manometer, inch (Δp)
First stage outlet, bar (p2)
Second stage outlet, bar (p3)
Page | 20

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Two Stage Air Compressor ME-TH-3810

Compressors may be classified into 4 major types, i.e.

2. The rotary compressor is used in similar application as the reciprocating type,

The unit is equipped with necessary measuring instruments and is on wheels.

Figure 1: Two-stage air compressor test set, air cooled

1. Inclined tube manometer

Figure 2: General arrangement diagram

T1 = Ambient air temperature

Type: Air cooled, two stage

First stage: Single or Twin cylinders with

Second stage: Single cylinder with

Motor dynamometer: 3.7 kW.

3.2. Measuring instruments:

Torque: Spring balance and torque arm = 120mm

Pressure: Pressure gauges at first stage and second stage outlets.

Compressor characteristics e.g. volumetric efficiency, isothermal efficiency, brake

Electricity: 440V 3Ph.

5.1. Air Compression

Where: C and n are constant.

5.2. Compression in Cylinder

Compression in cylinder with no clearance:

(a) Double Acting (b) Single Acting

Figure 5 p-V diagram for a cylinder with no clearance.

From equations (1) and (2), and assuming polytropic process;

If the compression is Isothermal process where n = 1, then equation (3) becomes:

Compression in cylinder with clearance (Figure 6A):

Normally, %C varies between 3 and 10%, depending on valve design.

Figure 6A p-V diagram

Figure 6B T-S diagram

1-2 = Polytropic compression, pVn = Constant

5.3. Two-Stage Air Compression:

Normally if a gas is to be compressed to a high pressure (more than 3 bars), it would be

Figure 7 Work diagram of two-stage air compressor with intercooler

Figure 8 p-V diagrams for two-stage air compressor

Figure 9 T-S diagrams for two-stage air compressor – isothermal process

Area 1-2-6-7 = Compression work done, stage 1

From pV = mRT we obtain,

And if the intercooler can work perfectly, T2 = T1

Where p1 = Atmospheric pressure, N/m2

6.1. Electrical power (EP)

6.2. Brake power (BP) or shaft power

Where N = Motor speed,

r = Length of dynamometer torque arm, m

Where Δp = pressure difference from manometer in inches

A 1 = dia of larger orifice

6.4. Isentropic power (Isen P)

6.5. Isothermal power (Iso P)

Isentropic efficiency (Isen eff %)

Vol eff % = Flow capacity × 100

From the recording data, the following calculations can be made:

Item Test Test Test Test Test

Motor speed 1, rpm (N1)

Compressor speed 2, rpm (N2)

Spring balance reading, kg (F)

Ambient temperature (T1)

Stage 1 compressor outlet (T2)

Stage 2 compressor inlet (T3)

Stage 2 compressor outlet (T4)

Water inlet (T5)

Water outlet (T6)

Air box manometer, inch (Δp)

First stage outlet, bar (p2)

Second stage outlet, bar (p3)