Part 4 - Two-Stage Piston Compressor PDF

Equipment for Engineering Education
,QVWUXFWLRQ0DQXDO
ET 500 Two-Stage Piston
Compressor Unit
G.U.N.T. Gerätebau GmbH

P.O. Box 1125
D-22881 Barsbüttel
Phone (040) 670854-0
Fax (040) 670854-42
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
All rights reserved G.U.N.T. Gerätebau GmbH, Barsbüttel 11/96
Instruction Manual
Publication No.: 916.000 00B 500 12 11/96

Table of Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Construction of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Process description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Installing the multifunction card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.2 Installing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Starting the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Conducting the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Measurements data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.2 Taking the measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Calculation of efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.2 Work sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1 Introduction
1.1 Compressor
The compressor is part of a system for generation

of compressed-air. Such systems are used
where compressed air is needed as an energy
source. This is particularly the case at work-si-
tes where inflammable ga ses f orm a po -
t e n t i a l explosion danger (e.g. in mines,
chemical industry, etc.), and also where the
compressed air is utilised to substitute electric
power.
- Mining: driving the machines.
- Chemical industry: process control enginee-
ring.
- Workshops, petrol stations: tools, paint spray
guns, tyre inflators.
- Assembly shops: automatic, pneumatic con-
trols.
A compressed-air generation system consists es-
sentially of:
- Compressor (1)
- Drive motor (2)
5 4 2 7 - Compressed-air tank (3)
1 - Safety valve (4)
6 - Pressure switch (electric drive)(5)

8
- Pressure gauge (6)
- Connecting pipes (7)
3
- Chassis (8).
Air coolers, pressure reducers, water
taps, etc. may also form a part of
such systems.
compressed-air generation system
The compressor is the main compo-
nent in any compressed-air generation system,
1 Introduction 1
where it is used to transform the supplied mecha-

nical energy into an increase in air pressure.
1.2 Function
Compressors are machines which convey gase-

ous media (in this case, air) from low-pressure
chambers into chambers with higher pressure.
The energy supplied for this purpose by machines,
e.g. electric motors or combustion engines, increa-
1 2 ses the pressure according to the intended use,
but also warms the air. Part of the heat is returned
1 Discharge valve to the ambient atmosphere by means of cooling

2 Intake valve
3 Cylinder fins.
3 4 Piston
5 Connectig rod The side illustration shows the basic design of a
4 6 Crankshaft
7 Crank housing reciprocating compressor.
8 Oil sump
The volume of air in the cylinder is compressed by
5 the upward movement of the piston and conveyed
by means of a discharge valve into the pressure
6
line.
7 On its downward stroke, the piston draws in fresh
air via the intake valve.
8 A crank mechanism, consisting of crankshaft and
connecting rod, produces the necessary upward-
downward movement of the piston from regular
Piston Compressor
rotation.
The oil required for lubricating the moving parts
gathers in the oil sump.
1 Introduction 2
The process which takes place in a compressor

can be illustrated by a so-called p,v- diagram.
Such p-v diagram shows the relation between the
pressure in the cylinder and the corresponding cylin-
der volume. The side illustrations give an indica-
tion of the individual compression phases. The
p,v-diagram has been turned clockwise through
p1 p2 90° to correspond to the piston stroke.
- Compression
Starting from point 1, bottom dead centre
v (BDC), the piston compresses the air in the
1
cylinder. The pressure increases with de-
creasing volume.
p1 p2 - Discharge
At point 2, the pressure in the cylinder has
2
reached the pressure p2 in the pressure line. The
discharge valve opens and the compressed air
v
1 flows into the pressure line.
- Re-expansion
At point 3, the piston has reached top dead
p1 p2
centre (TDC) and then reversed its direction.
3
The discharge valve closes and the air left in
2
the cylinder expands again. The pressure
v drops.
1
- Intake
At point 4, the pressure has dropped to the
p1 p2
ambient pressure p1 with the result that the
3 intake valve opens and fresh air flows into the
4 2 cylinder. This process continues until the pi-
v ston has reached bottom dead centre (BDC),
1 where (at point 1) the entire procedure starts
again.
1 Introduction 3
- Two-stage compression
If the pressure of the single-stage compression is
increased, both the counter-pressure and tem-
perature of the medium increase as well. The
compression ratio is limited by the tempera-
ture at which the oil-gas mixture explodes. In
the multi-stage compression, the medium is
cooled down between the single stages. This
decreases the volume losses, the powers on
the rods and the required power. The cooling
process allows a decrease of both the intake
temperature and the intake volume of the se-
cond stage.
In an ideal p-v diagram, the process of the
second stage begins directly after the isentro-
pic cooling of 1II and continues until the end
pressure 2II. If this is a single-stage compres-
sion, the process would hold isentropically wit-
hout stop until reaching the final pressure 2’.
The difference between these two process-
runs is the work saving.
3II 2II 2’
p3
Stage II
4II 1II 2
p2
3
Stage I
p1
4 1
v
1 Introduction 4
2 System description
2.1 Construction of the system
The complete system is mounted on a welded

square-steel-tube frame.
- Four castors for mobility and easy movement
of the system.
- Two castors are brakeable for secure standing.
- The dimensions allow moving the system
through normal door widths.
The apparatus contains a complete compressed-

air generation-system, including a two-stage built-
in compressor and a compressed-air tank.
D IN D IN
0 16 0 1,6
bar bar
Kl .1 ,6 Kl .1 ,6
- Power supply needed to operate the system is

230V / 50Hz.
- Low-noise operation by damped system bea-
rings.
- All measurement techniques and armatures
0
DI N
bar
16
Kl. 1,6
are according to the latest industrial stand-
ards.
- Large intake damper smoothens the volume
flow and holds the measuring sensors.
All electrical elements needed for operation are

placed together in one switch cabinet.
- Main switch and emergency-stop switch.
- Digital displays for all measured values.
- Switch for compressor.
2 System description 5
5 6 7 8 9 10 11 12
4
3 13
1 17 16 15 14
1. Laboratory trolley 10. Orifice for Flow measurement

2. Drive motor 11. Differential pressure transmitter
3. Silencer 12. Control cabinet with digital displays
4. Pressure vessel 2nd stage 13. Resistance thermometer
5. Pressure transmitter 14. Pressure vessel and intercooler 1st stage
6. Pressure gauge 15. 1st compressor stage
7. Safety valve 16. Two cylinder piston compressor
8. Blow off valve 17. 2nd compressor stage
9. Intake vessel
2 System description 6
2.2 Process description
The ET 500 Piston-Compressor Test-Rig is a two-

stage compressor system. The air is sucked into
tank 1 via a measurement nozzle. Tank 1 serves
as a moderation (stabilisation) zone in addition to
supporting the measurement sensors for the inta-
ke stage. The intake volume is determined by the
measurement nozzle. A small pressure tank is
located between the first and second stages; it is
used for the cooling stage. The compressed air is
pressed into the tank 2 (pressure-air tank) through
a cooling pipe.
For the purpose of a stationary operating condition,
the compressed air can be blown through an
outlet valve equipped with an acoustic silencer.
Safety valve and pressure switch complete the
system.
3 Safety
M EI
PI
PI 04
TI TI
04 03
Tank 2
TI PI
PI 01 01
PI PD
Tank 1
TI
02
PI
02
3 Safety 7
When operating the test rig, the following must be

observed.
- DANGER! Be careful when touching the

electrical parts.
Danger of electric shock.
Pull the plug out of the mains. It should be dealt
with by specialised personnel only.
- DANGER! Be careful of the hot surfaces

and parts.
Danger of burns.
Let the unit cool down before service.
- DANGER! Be careful of the drive.

Danger of injuries from rotating parts.
Protection cage must be always installed du-

ring operation.
3 Safety 8
4 Operation
In this section, the steps for a frictionless operation

of the test rig are introduced.
This instruction manual is valid only for the con-
temporary manufacturer’s unit.
4.1 Installing the multifunction card
The card should be installed in the PC as follows:

- Switch off the PC and pull the power cord.
- Open the PC housing.

- Find a free slot on the motherboard (make sure
that the address 0320 HEX is not yet assigned
in the computer.)
- Insert the card and screw down.
- Close the PC housing.
4.2 Installing the software
The software is installed on the PC with the aid of

a user guidance system. Proceed as follows:
- Switch on the PC and start Windows.
- Place the first installation disk in the floppy
drive.
- Open the File Manager under Windows
- Select the drive in which the installation disk
has been inserted.
- Find the setup.exe file and activate with a dou-
ble-click.
Installation is then carried out automatically. A
special icon is generated under Windows, which is
used to start the user software.
Before starting the experiment, the following points
should be observed.
4 Operation 9
4.3 Starting the system
- Place the system on a plane surface and secu-

re it against rolling away by enabling the bra-
kes.
- Plug in the mains power supply.
- Check the oil level when motor is OFF
(also see service).
- Turn the system ON by pulling the emergency-off
switch and turning ON the main switch.
- Turn the compressor ON.
Turn the main switch ON , button I on the

pressure switch ON (the switch is between the
two upper pressure tanks). The compressor swit-
ches OFF at about 12 bar while the outlet valve
being closed. It switches ON again when the
pressure drops to about 10 bar. The ON/OFF
pressure is adjustable on the pressure switch.
- Turn the compressor OFF.
Always press first the O on the pressure
switch, so that the bleed valve is activated. The
bleed valve vents the connecting pipes to the
compressor, for smooth motor run. Turn OFF
the main switch on the switch cabinet.
4 Operation 10
4.4 Maintenance
Maintenance of the system is limited to the main-

tenance of the built-in compressor. To maintain the
compressor, refer to instruction manual of the
compressor made by KAESER.
The technical descriptions stated here are needed
only for certain operating compressors. Within the
frame of laboratory operations, the compressor is
operated occasionally, so that the maintenance is
limited to oil filling and checking the oil-level.
Oil level and changing the oil
Oil level:
Before start-up, check the compressor for oilavailability.
- Check the oil level at the oil mark in the viewing
window. Oil level must be at least up to the
Viewing window max
lower mark, otherwise add more oil up to the
upper mark.
Changing the oil:

Changing the oil only when the working tempera-
ture is on normal working level
- Discharge the oil through the oil drain plug
- For clenning the crankcase use only the recom-
mended lubricating oil.
- Add oil through the oil inlet up to the mark.
Oil mark min
ATTENTION! Do not forget to close the oil drain
plug before adding oil.
For periodical maintenance and oil specification,

refer to section 6.1 Technical Data.
4 Operation 11
5 Conducting the test
5.1 Measurements data
Pressure:
The digital displays show the absolute pressure of
the measurement positions in bar. The manome-
ters mounted on the tanks show the overpressure
of the measurement position in bar.
Differential pressure / intake volume:

Venturi tube
The differenial pressure ∆p of a Venturi tube is

proportional to the flow
. 2 ∆p
V =Ad √
 ρ
.
Tank where V in m3/s, ∆p in Pa and ρ in kg/m3
and Ad=1,131∗10−4 m2
The density ρ of air depends on temperature and
ambient pressure
100 ⋅ p0
∆p ρ = 287 ⋅ (T + 273)
with ρ in kg/m3, p0 in mbar and T in °C.

The differential pressure ∆p is formed in the sy-
stem from the environment pressure and the pres-
sure in the smallest cross section of the Venturi
tube. The output is displayed digitally (in mbar)
after being transformed by the differential pressure
transducer.
5 Conducting the test 12

Temperature:
The temperatures are measured by means of four
resistance thermometers. The values are display-
ed digitally. Transmitters converted the measured
values to analog signals.
Power:
The power of the compressor motor is measured
by means of a power transmitter. The measured
value is also displayed digitally.

5.2 Taking the measurements
The measurements listed should not be viewed as

guideline or calibration values which must be ad-
hered to in all circumstances. Deviations may oc-
cur to a greater or lesser extent in your own
experiments, depending on the design of the indi-
vidual components and ambient conditions.
- Turn the compressor ON (see section 4.3). If it

does not run, the voltage-overflow switch, that
is mounted directly on the motor, may have
been switched off - press it again.

- Let the system run until a constant pressure p3
has been reached. Set the desired final pres-
sure with the outlet valve and note down the
measurements.
.
p1 t1 p2 t2 t3 p4 t4 ∆p V Pel. time 1)
in in in in in in in in in in Watt in
bar °C bar °C °C bar °C mbar l/min min
0,99 23,0 3,4 127,1 58,8 11,7 151,6 7,4 239,51 2550 3
0,99 22,9 3.4 126,1 58,4 11,0 146,5 7,4 239,51 2510 3
0,99 22.8 3.3 125,1 58.0 10.0 141,5 7,5 241,12 2460 5
0,99 22,6 3.3 123,4 57,2 9,0 133,4 7,5 241,12 2400 5
0,99 22,3 3.2 121,0 56,1 8.2 124,2 7.6 242,73 2350 5
0,99 21,9 3.1 118,1 54,7 6,7 108,7 7,6 242,73 2240 5
1) Time needed for measurements to become steady

5.3 Calculation of efficiency
In order to determine efficiency of compressor, the

hydraulic power must be calculated. The iso-
thermal power of compression with inter-
cooling is calculated as follows:
. p
Phydr. = p 1 ⋅ V 1 ⋅ ln p 4
1
.
where p in Pa and V in m3/s
The efficiency is the ratio of hydraulic power to
electric power input.
P
η = Phydr.
el.

6 Appendix
6.1 Technical data
Main dimensions
length 1520 mm
width 750 mm
height 1500 mm
weight approx. 260 kg
power supply 230 V, 50 Hz, 16 A
Compressor
cylinders 2, V-shape
number of stages 2
max. pressure: 35 bar
(used pressure 12 bar)
Intake flow : 250 l/min.
speed 710 rpm
maintenance intervals first oil service after 50
operation hours, further services
after 500 hours or after
1 year
oil specification compressor oil conforming with
DIN 51 506, group VG 30
(SAE 30)
oil volume approx. 1.5 litre
Drive motor:
power 2,2 kW
speed 3000 rpm
power supply 230 V, 50 Hz
Intake vessel:
capacity 20 l
max. pressure 16 bar
Intercooler vessel:
capacity 5 l
Pressure vessel:
capacity 20 l
6 Appendix 16
Differential pressure transmitter:

measuring range 0 - 10 mbar
output signal 0 - 10 V DC
auxiliary power 24 V DC
Pressure transmitter:
measuring range 1x 0 - 1.6 bar abs.
and 2x 0 - 16 bar abs.
auxiliary power 24 V DC
Resistance thermometer with transmitter:

type Pt 100
measuring range 0 - 200 °C

auxiliary power 230 V, 50 Hz
Power transmitter:
measuring range 0 - 2500 W
auxiliary power 230 V, 50 Hz
Digital display with power supply for transmitter:

display 3 1/2 digit
power supply for transmitter 24 V DC
power supply 230 V, 50 Hz
Multifunction card
Analog inputs: 16, 0 - 10 VDC
Analog outputs: 2, 0 - 10 VDC
Digital inputs: 8, TTL
Digital outputs: 8, buffered TTL
Counter: 1, 16 bit
Software
Runtime version of visual designer 4.0 completely configured.
The software enables for online representation
of measured values, graphically & numerically.
6 Appendix 17
p1 t1 p2 t2 t3 p4 t4 ∆p Pel. Time
6.2
V.
in in in in in in in in in in Watt in
bar °C bar °C °C bar °C mbar l/min min
ET 500
6 Appendix
Work sheet
Measurements table
Piston Compressor Test Rig
18

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Equipment for Engineering Education

G.U.N.T. Gerätebau GmbH

Publication No.: 916.000 00B 500 12 11/96

2.1 Construction of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Process description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.1 Installing the multifunction card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Conducting the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.1 Measurements data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

The compressor is part of a system for generation

6 - Pressure switch (electric drive)(5)

where it is used to transform the supplied mecha-

Compressors are machines which convey gase-

1 Discharge valve to the ambient atmosphere by means of cooling

The process which takes place in a compressor

2.1 Construction of the system

The complete system is mounted on a welded

The apparatus contains a complete compressed-

- Power supply needed to operate the system is

All electrical elements needed for operation are

1. Laboratory trolley 10. Orifice for Flow measurement

2.2 Process description

The ET 500 Piston-Compressor Test-Rig is a two-

When operating the test rig, the following must be

- DANGER! Be careful when touching the

- DANGER! Be careful of the hot surfaces

- DANGER! Be careful of the drive.

Protection cage must be always installed du-

In this section, the steps for a frictionless operation

4.1 Installing the multifunction card

The card should be installed in the PC as follows:

- Open the PC housing.

4.2 Installing the software

The software is installed on the PC with the aid of

4.3 Starting the system

- Place the system on a plane surface and secu-

Turn the main switch ON , button I on the

Maintenance of the system is limited to the main-

Oil level and changing the oil

Changing the oil:

For periodical maintenance and oil specification,

5 Conducting the test

5.1 Measurements data

Differential pressure / intake volume:

The differenial pressure ∆p of a Venturi tube is

with ρ in kg/m3, p0 in mbar and T in °C.

5 Conducting the test 12

5 Conducting the test 13

5.2 Taking the measurements

The measurements listed should not be viewed as

- Turn the compressor ON (see section 4.3). If it

been switched off - press it again.

1) Time needed for measurements to become steady

5 Conducting the test 14

5.3 Calculation of efficiency

In order to determine efficiency of compressor, the

5 Conducting the test 15

6.1 Technical data

power supply 230 V, 50 Hz, 16 A

Differential pressure transmitter:

Resistance thermometer with transmitter:

measuring range 0 - 200 °C

Digital display with power supply for transmitter: