Multi (Two) Stage

Reciprocating Air Compressor

SMT-HT-17

OPERATION MANUAL
 Note
This manual has been made accurate to the most of our knowledge, however there is no
liability for errors. If there is an error discovered, please notify the company with complete
details. Experimental results provided are for the sole purpose of guidance and are not
guaranteed to be the answers obtained for any given apparatus. Variables involved may or
may not affect the experimental results.
 Warning
This unit has been designed to be safe for users during operation. As with any other
sophisticated piece of equipment, danger exist if equipment is mishandled or not
maintained properly. Presence of competent personnel during the operation of equipment
is advised.
It is the user’s responsibility to exercise safe practices during the operation of this unit.

Heavy Hot surface Pressurized system

Table of Contents

1. THEORY ....................................................................................................................................... 1
1.1 Introduction ............................................................................................................................ 1
1.2 Air Compression Theory ............................................................................................................. 1
1.3 Compression in Cylinder .......................................................................................................... 2
1.3.1 Compression in cylinder with no clearance ............................................................................. 2
1.3.2 Compression in cylinder with clearance ................................................................................... 4
1.4 Two-Stage Air Compression ............................................................................................... 4
1.5 Performance Index: ............................................................................................................ 5
1.5.1 Electrical power (EP) ............................................................................................................. 5
1.5.2 Flow Rate (qm) ...................................................................................................................... 5
1.5.3 Torque (T) .............................................................................................................................. 6
1.5.4 Brake power (BP) or shaft power ......................................................................................... 6
1.5.5 Isentropic Power (isen P) ...................................................................................................... 6
1.5.6 Isothermal Power (Iso P) ....................................................................................................... 7
1.5.7 Isentropic efficiency (Isen eff %) ........................................................................................... 7
1.5.8 Isothermal efficiency (Iso eff %) ........................................................................................... 7
1.5.9 Volumetric efficiency (vol eff %) ........................................................................................... 7
2 EXPERIMENT ........................................................................................................................... 8
2.1 Objective: ............................................................................................................................ 8
2.3 Observations: ........................................................................................................................... 9
2.3 Sample Calculations: ........................................................................................................ 10
3 Phase Flow Diagram: ............................................................................................................ 24
4 SAFETY PRECAUTIONS: ......................................................................................................... 28
 General Description:
he ESOLs Two Stage Air compressor unit is reciprocating type and consist of Electric motor
having capacity of 5 HP. Heat Exchanger is present between two stages of compressor. Air
receiver tank has a safety valve and safety switch as well as drain valve. The is equipped
2with necessary measuring instrument and wheels.

7
6

5
9
3 10
4
11

12

13

1 Figure1: Parts Identification and set-up of two stage compressor

1. Air Receiver Tank 2.Electric Motor 3. 1st Stage 4. 2nd Stage

5. Intermediate Tank 6. Intercooler 7. LCD Display 8. Power Analyzer

9. Air Intake tank 10. Power Switch 11. Emergency Switch 12. Frame

13. Safety Switch

Specifications:
The Unit consists of the followings:

• Electric power
HP = 5
Power (Electric) = 3.7285 kW

• Compressor Type
Two Stage Reciprocating
Compressor speed = 1000rpm
Air receiver tank capacity = 200 L

• Intermediate Tank
• Air Intake tank with orifice
• Intercooler

• Power
380-420 volts, 50 Hz

• Compressor Hydraulic motor oil number 46

• Pipes
Stainless steel pipes
Diameter: 12mm
 1. THEORY
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., reciprocating type, rotary type,
centrifugal type and axial flow type.
The reciprocating compressor is suitable for work application that requires high
pressure but not so high flow rate.
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.
The centrifugal compressor is suitable for work application that requires not so high
pressure but very high flow rate.
The axial flow compressor is similar to the centrifugal compressor but for less pressure
and more flowrate.
In this manual, only reciprocating air compressor for high pressure will be discussed as it is
being most widely used today.

1.2 Air Compression Theory

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 1.
Pressure
2

Volume
Figure 1: p-V diagram of air compression from state (1) to state (2)

1
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.

1.3 Compression in Cylinder

1.3.1 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 analyse 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 2.

Double acting Single Acting

Figure 2: Double acting and single acting cylinder

2
 p

3 2

n
pV = C

0 1
V

Figure 3: p-V diagram for a cylinder with no clearance.

The Figure 3 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:
1 2 3 0

Wcycle =  pdV+ pdV+ pdV+ pdV

0 1 2 3

Assuming polytropic process

If the compression is Isothermal process where n = 1, then the above equation becomes:

3
1.3.2 Compression in cylinder with clearance

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).

Where V3 = Clearance Volume

V1-V3 = Swept Volume

3' T2 2
3

n
pV
m
pV

4' T1
4 1

Figure 4: PV diagram

The p-V diagram of figure 4 is similar to that of figure 3 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.

1.4 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

4
is air cooled finned tube. However, for education purpose, the intercooler may be water
cooled.

1st stage Intermediate

Intercooler 2nd stage
tank

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. 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.

1.5 Performance Index:

1.5.1 Electrical power (EP)
EP (in W) is the electrical power supplied to the motor to drive an air compressor.
EP = V x I

Where V = Voltage, Volts

I = Current, Ampere

This electrical power may also be directly measured by a power analyzer.

1.5.2 Flow Rate (qm)

While,
Cf = coefficient of flow =0.63
D1=Larger Diameter of orifice
D2=Smaller Diameter of an orifice
d = D2 /D1
ρ=1.2 kg/m3

5
1.5.3 Torque (T)

We should know electric power of motor (Pelectric),

Then we have;

 = angular speed;

while, N = speed in RPM

Putting value of  we get

1.5.4 Brake power (BP) or shaft power

This is the power (in W) that the motor supplies to the compressor.

1.5.5 Isentropic Power (isen P)

This is the theoretical Power from the theory of isentropic compression
process (Reversible Isentropic process):

6
Where: k = CV / Cp
CV= Specific heat of gas at constant volume, kJ/kg K
Cp = Specific heat of gas at constant pressure, kJ/kg K
T = Temperature, K
p = Pressure, N/m2
Subscript 1 = Inlet
Subscript 2 = Outlet or discharge
qm = mass flow rate, kg/s

1.5.6 Isothermal Power (Iso P)

This is the minimum horsepower for the compression process calculated as
follows:

where, P = Pressure, N / m2
V =Volume per unit time, m / sec

1.5.7 Isentropic efficiency (Isen eff %)

1.5.8 Isothermal efficiency (Iso eff %)

1.5.9 Volumetric efficiency (vol eff %)

7
2 EXPERIMENT
2.1 Objective:

To find the;
1. Flow rate
2. Torque
3. Brake Power
4. Isothermal Power
5. Isothermal efficiency
6. Isentropic efficiency
7. volumetric efficiency

2.2 Procedure:

• Connect the 3-phase power supply to the compressor.

• Switch on the unit by turning the knob to the ‘ON’ position.
• Make sure the toggle switch button is selected to ‘LCD Mode’.
• Now select the configuration you want to operate. The unit allows for studying
different compression situations:
a) Compression in one stage – low pressure piston.
b) Compression in one stage – high pressure piston.
c) Two stages without intercooling.
d) Two stages with intercooling.
All of the circuits present the respective safety systems; relief valves, check
valve such as safety pressure switch.

• Once the desired configuration is selected, touch the power button on LCD
such that the power button turns green from red
• Toggle the compressor button to ‘ON’ position.
• Compressor will start
• Open the outlet valve such that the unit operate on a constant discharge
pressure.
• Once the reading stabilized, record the rereading’s

Record the following data:

• Motor speed and compressor speed.

• Note down Pressures after stage 1 and stage 2, pressure in the receiver and the
differential pressure.
• Temperatures of ambient air, after stage 1, after stage 2.
• Adjust the pressure in the air receiver tank to different value and repeat the
experiment.
• The compressor may be further tested at lower compressor speeds and at
various air receiver tank pressures.

8
2.3 Observations:

P1 in T1 in P2 in T2 in P3 in T3 in P4 in T4 in Compressor Motor ∆p Power

bar °C bar °C bar °C bar °C speed speed in KW

P1: Ambient pressure

T1: Ambient temperature
P2: 1st stage Outlet pressure
T2: 1st stage Outlet temperature
P3: Pressure after intercooler
T3: Temperature after intercooler
P4: 2nd stage outlet pressure
T4: 2nd stage outlet temperature
∆p: Inlet air pressure differential

Air inlet tank orifice internal diameter = 15 mm

Air box diameter = 100 mm

Air compressor, 1st stage bore 90 mm, Stroke 85 mm

2st stage bore 50 mm, Stroke 85 mm

9
 2.3 Sample Calculations:

COMPRESSOR CONFIGURATION: 2 STAGES WITHOUT INTERCOOLING

P1 in T1 in P2 in T2 in P3 in T3 in P4 in T4 in Compressor Motor ∆p Power
bar °C bar °C bar °C bar °C speed speed (kpa) in KW
1 22 1.2 109 1 62 4 147 630 900 0.51 1.0

Cylinder Displacement
𝜋 𝜋
Swept volume / cycle = (B1)2(S1) + (B2)2(S2)
4 4

3.14 3.14
= (0.09)2 (0.85) + (0.05)2 (0.85)
4 4

= 0.000707 m3
Theoretical Compressor Displacement = (0.000707) x RPM
= (0.000707) x 630
= 0.445 m3/min
= 0.00742 m3/s
Electric Power (EP):
Electric power = 1 kW
Flow rate (qm):

𝐶𝑓 𝜋 𝐷22 2 ∆𝑃
qm = xρx√
4 ρ(1−𝑑 4 )

Cf = coefficient of flow =0.63

D1=Larger Diameter of orifice = 0.1 m
D2=Smaller Diameter of an orifice = 0.015m
d = D2 /D1 =0.015/0.100 = 0.15
ρ=1.2 kg/m3

(0.63)(3.14) (0.0152 ) 2 (0.51)×1000

qm = x 1.2 x √ ∵ 1kpa = 1000 Pa
4 1.2(1−0.154 )

qm = 0.00389 kg/s

qv = 0.00324 m3/s

10
Torque:
𝐸𝑃
T=
𝜔
2𝜋𝑁
ω=
60
while ω = angular speed
N = RPM of motor

1000 ×60
T=
2 ×3.14 ×900

T = 10.61 Nm

Brake power (BP) or shaft power:

BP = Torque x ω
2𝜋𝑁
BP = T x
60
2×3.14×900
BP = 10.61 x
60

BP = 1000W
Isentropic power:
𝑃2 𝑘−1 𝑃4 𝑘−1
Isen P = qm x Cp x T1 [( ) 𝑘 – 1] + qm x Cp x T2 [( ) 𝑘 – 1]
𝑃1 𝑃2

Where: k = CV / Cp

CP = 1.005 kJ/kg K
1.4−1 1.4−1
2.2 5
= 0.00389 x 1.005 x 295 [( ) 1.4 – 1] + 0.00389 x 1.005 x 382 [( ) 1.4 – 1]]
1 2.2

= 1.15 [0.252) + 1.493(0.264)]

= 0.683 kW
= 683 W

2.4.7 Isothermal Power (Iso P)

𝑃4
Iso P = Pa x qv ln( )
𝑝𝑎
5
= 1 x 0.0035 ln( ) x 100000 ∵ 1bar = 100000 N/m2
1.013
= 558 W ∵ Nm/s = W

11
Isentropic Efficiency
𝐼𝑠𝑒𝑛 𝑃
Isen eff = x 100
𝐵𝑃
683
= x 100
1000

= 68.3%
Isothermal Efficiency
𝐼𝑠𝑜 𝑃
Iso eff = x 100
𝐵𝑃
558
Iso eff = x 100
1000
= 55.8 %

Volumetric Efficiency
𝑞𝑣
Vol eff = 𝑠𝑤𝑒𝑝𝑡 𝑣𝑜𝑙 x 100
× 𝑠𝑝𝑒𝑒𝑑
𝑐𝑦𝑐𝑙𝑒

qm
qv =
density of air
0.00389
qv = =
1.2
= 0.00324 m3/s
0.00324
Vol eff = x 100
0.0074
Vol eff = 43.7 %

COMPRESSOR CONFIGURATION: 2 STAGES WITH INTERCOOLING

P1 in T1 in P2 in T2 in P3 in T3 in P4 in T4 in Compressor Motor ∆p Power
bar °C bar °C bar °C bar °C speed speed (kpa) in KW
1 22 1.8 109 0.8 30 4 134 635 908 0.49 1.1

Cylinder Displacement
𝜋 𝜋
Swept volume / cycle = (B1)2(S1) + (B2)2(S2)
4 4

3.14 3.14
= (0.09)2 (0.85) + (0.05)2 (0.85)
4 4

= 0.000707 m3
Theoretical Compressor Displacement = (0.000707) x RPM
= (0.000707) x 635
= 0.448 m3/min

12
 = 0.00748 m3/s
Electric Power (EP):
Electric power = 1.1 kW
Flow rate (qm):

𝐶𝑓 𝜋 𝐷22 2 ∆𝑃
qm = xρx√
4 ρ(1−𝑑 4 )

Cf = coefficient of flow =0.63

D1=Larger Diameter of orifice = 0.1 m
D2=Smaller Diameter of an orifice = 0.015m
d = D2 /D1 =0.015/0.100 = 0.15
ρ=1.2 kg/m3

(0.63)(3.14) (0.0152 ) 2 (0.49)×1000

qm = x 1.2 x √ ∵ 1kpa = 1000 Pa
4 1.2(1−0.154 )

qm = 0.00381 kg/s

qv = 0.00318 m3/s

Torque:
𝐸𝑃
T=
𝜔
2𝜋𝑁
ω=
60
while ω = angular speed
N = RPM of motor

1100 ×60
T=
2 ×3.14 ×908

T = 11.56 Nm

Brake power (BP) or shaft power:

BP = Torque x ω
2𝜋𝑁
BP = T x
60

13
 2×3.14×908
BP = 11.56 x
60

BP = 1100 W
Isentropic power:
𝑃2 𝑘−1 𝑃4 𝑘−1
Isen P = qm x Cp x T1 [( ) 𝑘 – 1] + qm x Cp x T2 [( ) 𝑘 – 1]
𝑃1 𝑃2

Where: k = CV / Cp

CP = 1.005 kJ/kg K
1.4−1 1.4−1
2.8 5
= 0.00389 x 1.005 x 295 [( ) 1.4 – 1] + 0.00389 x 1.005 x 382 [( ) 1.4 – 1]]
1 2.8

= 1.15 [0.342) + 1.493(0.18)]

= 0.662kW
= 662 W

Isothermal Power (Iso P)

𝑃4
Iso P = Pa x qv ln( )
𝑝𝑎
5
= 1 x 0.00318 ln( ) x 100000 ∵ 1bar = 100000 N/m2
1.013
= 507 W ∵ Nm/s = W

Isentropic Efficiency
𝐼𝑠𝑒𝑛 𝑃
Isen eff = x 100
𝐵𝑃
662
= x 100
1100

= 60.1%
Isothermal Efficiency
𝐼𝑠𝑜 𝑃
Iso eff = x 100
𝐵𝑃

507
Iso eff = x 100
1100
= 46 %

Volumetric Efficiency
𝑞𝑣
Vol eff = 𝑠𝑤𝑒𝑝𝑡 𝑣𝑜𝑙 x 100
× 𝑠𝑝𝑒𝑒𝑑
𝑐𝑦𝑐𝑙𝑒

qm
qv =
density of air

14
 0.00381
qv = =
1.2
= 0.00318 m3/s
0.00324
Vol eff = x 100
0.0074
Vol eff = 42.5 %

COMPRESSOR CONFIGURATION: SINGLE STAGE WITH LOW PRESSURE CYLINDER

P1 in T1 in P2 in T2 in P3 in T3 in P4 in T4 in Compressor Motor ∆p Power
bar °C bar °C bar °C bar °C speed speed (kpa) in KW
1 22 4.7 112 - - 4 - 640 915 0.45 0.9

Cylinder Displacement
𝜋
Swept volume / cycle = (B1)2(S1)
4

3.14
= (0.09)2 (0.085)
4

= 0.00054 m3
Theoretical Compressor Displacement = (0.00054) x RPM
= (0.00054) x 640
= 0.345 m3/min
= 0.0057 m3/s
Electric Power (EP):
Electric power = 0.9 kW
Flow rate (qm):

𝐶𝑓 𝜋 𝐷22 2 ∆𝑃
qm = xρx√
4 ρ(1−𝑑 4 )

Cf = coefficient of flow =0.63

D1=Larger Diameter of orifice = 0.1 m
D2=Smaller Diameter of an orifice = 0.015m
d = D2 /D1 =0.015/0.100 = 0.15
ρ=1.2 kg/m3

(0.63)(3.14) (0.0152 ) 2 (0.45)×1000

qm = x 1.2 x √ ∵ 1kpa = 1000 Pa
4 1.2(1−0.154 )

15
 qm = 0.00365 kg/s

qv = 0.00304 m3/s

Torque:
𝐸𝑃
T=
𝜔
2𝜋𝑁
ω=
60
while ω = angular speed
N = RPM of motor

900 ×60
T=
2 ×3.14 ×915

T = 9.39 Nm

Brake power (BP) or shaft power:

BP = Torque x ω
2𝜋𝑁
BP = T x
60
2×3.14×915
BP = 9.39 x
60

BP = 900 W
Isentropic power:
𝑃2 𝑘−1
Isen P = qm x Cp x T1 [( ) 𝑘 – 1]
𝑃1

Where: k = CV / Cp

CP = 1.005 kJ/kg K
1.4−1
5.7
= 0.00389 x 1.005 x 295 [( ) 1.4 – 1]
1

= 1.15 (0.644)
= 0.740kW
= 740 W

Isothermal Power (Iso P)

𝑃2
Iso P = Pa x qv ln( )
𝑝𝑎

16
 5.7
= 1 x 0.00304 ln( ) x 100000 ∵ 1bar = 100000 N/m2
1.013
= 529 W ∵ Nm/s = W

Isentropic Efficiency
𝐼𝑠𝑒𝑛 𝑃
Isen eff = x 100
𝐵𝑃
740
= x 100
900

= 82.2%
Isothermal Efficiency
𝐼𝑠𝑜 𝑃
Iso eff = x 100
𝐵𝑃

529
Iso eff = x 100
900
= 58.7 %

Volumetric Efficiency
𝑞𝑣
Vol eff = 𝑠𝑤𝑒𝑝𝑡 𝑣𝑜𝑙 x 100
× 𝑠𝑝𝑒𝑒𝑑
𝑐𝑦𝑐𝑙𝑒

0.00304
Vol eff = x 100
0.0057
Vol eff = 53.3 %

COMPRESSOR CONFIGURATION: SINGLE STAGE WITH HIGH PRESSURE CYLINDER

P1 in T1 in P2 in T2 in P3 in T3 in P4 in T4 in Compressor Motor ∆p Power
bar °C bar °C bar °C bar °C speed speed (kpa) in KW
1 22 - - - - 4 107 640 915 0.1 0.9

Cylinder Displacement
𝜋
Swept volume / cycle = (B2)2(S2)
4

3.14
= (0.05)2 (0.085)
4

= 0.000166 m3
Theoretical Compressor Displacement = (0.000166) x RPM

17
 = (0.000166) x 640
= 0.106 m3/min
= 0.0017 m3/s
Electric Power (EP):
Electric power = 0.9 kW
Flow rate (qm):

𝐶𝑓 𝜋 𝐷22 2 ∆𝑃
qm = xρx√
4 ρ(1−𝑑 4 )

Cf = coefficient of flow =0.63

D1=Larger Diameter of orifice = 0.1 m
D2=Smaller Diameter of an orifice = 0.015m
d = D2 /D1 =0.015/0.100 = 0.15
ρ=1.2 kg/m3

(0.63)(3.14) (0.0152 ) 2 (0.1)×1000

qm = x 1.2 x √ ∵ 1kpa = 1000 Pa
4 1.2(1−0.154 )

qm = 0.00172 kg/s

qv = 0.00143 m3/s

Torque:
𝐸𝑃
T=
𝜔
2𝜋𝑁
ω=
60
while ω = angular speed
N = RPM of motor

900 ×60
T=
2 ×3.14 ×915

T = 9.39 Nm

Brake power (BP) or shaft power:

BP = Torque x ω

18
 2𝜋𝑁
BP = T x
60
2×3.14×915
BP = 9.39 x
60
BP = 900 W
Isentropic power:
𝑃4 𝑘−1
Isen P = qm x Cp x T1 [( ) 𝑘 – 1]
𝑃1

Where: k = CV / Cp

CP = 1.005 kJ/kg K
1.4−1
5
= 0.00389 x 1.005 x 295 [( ) 1.4 – 1]
1

= 1.15 (0.583)
= 0.671kW
= 671 W

Isothermal Power (Iso P)

𝑃4
Iso P = Pa x qv ln( )
𝑝𝑎
5
= 1 x 0.00143 ln( ) x 100000 ∵ 1bar = 100000 N/m2
1.013
= 230 W ∵ Nm/s = W

Isentropic Efficiency
𝐼𝑠𝑒𝑛 𝑃
Isen eff = x 100
𝐵𝑃
671
= x 100
900

= 74.5%
Isothermal Efficiency
𝐼𝑠𝑜 𝑃
Iso eff = x 100
𝐵𝑃

230
Iso eff = x 100
900
= 25.5 %

Volumetric Efficiency
𝑞𝑣
Vol eff = 𝑠𝑤𝑒𝑝𝑡 𝑣𝑜𝑙 x 100
× 𝑠𝑝𝑒𝑒𝑑
𝑐𝑦𝑐𝑙𝑒

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 0.00143
Vol eff = x 100
0.0017
Vol eff = 84.1 %

DRYNESS CALCULATION FOR 2 STAGES WITH INTERCOOLING

P1 in T1 P2 in T2 in P3 in T3 P4 in T4 Compressor Motor ∆p Power Humidity
bar in bar °C bar in bar in speed speed (kpa) in KW (%)
°C °C °C
1 22 1.8 109 0.8 30 4 100 635 908 0.49 1.1 53.7

The maximum content of water in air at saturated conditions decrease with pressure and increase
with temperature as indicated in the diagrams below.

From our given data and from above table and graph we can see that the water content in saturated
air entering the compressor is approximately 1.8 10-2 kg/m3 free air (0.018 kgwater/m3air).

The amount of water with 53.7% saturation can be calculated as:

0.018 ×53.7%
=
100%

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 = 0.00967 kgwater/m3air

The water content in the 100% saturated air leaving the compressor at 4 bar and 100°C is
approximately 0.19 10-2 kg/m3 free air (0.0019 kgwater/m3air).

The water extracted in the compressor can be calculated as

0.00967 kgwater/m3air - 0.0019 kgwater/m3air

= 0.0077 kgwater/m3air

Note:
Reference link for this calculation is given below:
https://www.engineeringtoolbox.com/water-content-compressed-air-d_1275.html

PV DIAGRAM OF 2 STAGES WITH INTERCOOLING

P1 in T1 in P2 in T2 in P3 in T3 in P4 in T4 in Compressor Motor ∆p Power
bar °C bar °C bar °C bar °C speed speed (kpa) in KW
0 22 1.8 109 0.8 30 4 134 635 908 0.49 1.1

Flow rate (qm):

𝐶𝑓 𝜋 𝐷22 2 ∆𝑃
qm = xρx√
4 ρ(1−𝑑 4 )

Cf = coefficient of flow =0.63

D1=Larger Diameter of orifice = 0.1 m
D2=Smaller Diameter of an orifice = 0.015m
d = D2 /D1 =0.015/0.100 = 0.15
ρ=1.2 kg/m3
(0.63)(3.14) (0.0152 ) 2 (0.49)×1000
qm = x 1.2 x √ ∵ 1kpa = 1000 Pa
4 1.2(1−0.154 )

qm = 0.00381 kg/s

qv = V1= 0.00318 m3/s

We can find the volume V2 by following equation:

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 P1.V 1 P 2.V 2
=
T1 T2
P1.V 1.T 2
V2=
T 1.P 2
Where:
P1=1 BAR absolute
P2= 2.8 BAR absolute
T1= 295K
T2=382K
V1= 0.00318 m3/s
1 x 0.00318 x 382
V2=
295 x 2.8

V 2 = 0.00147 m3 / s

Similarly, to find V3,

P 2.V 2 P3.V 3
=
T2 T3
P 2.V 2.T 3
V2=
T 2.P3
Where:
P2= 2.8 BAR absolute
T2=382K
V2= 0.00174 m3/s
P2=P3= 2.8 BAR absolute (assuming that intercooling occurs at constant pressure)
T3=303K
2.8 x 0.00147 x 303
V3 =
382 x 2.8

V 3 = 0.0011 m3 / s

Similarly, to find V4,

P3.V 3 P 4.V 4
=
T3 T4
P3.V 3.T 4
V4=
T 3.P 4
Where:
P2= P3= 2.8 BAR absolute (assuming that intercooling occurs at constant pressure)
T3=303K
V3= 0.0011 m3/s
P4= 5 BAR absolute
T4=407K

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 2.8 x 0.0011x 407
V4=
303 x 5

V 4 = 0.00082 m3 / s

P Delivery pressure
2ND STAGE
P4

Intercooler pressure (occur at constant

pressure)
P2=P3

1ST STAGE
Suction pressure

P1

V4 V3 V2 V1

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3 Phase Flow Diagram:

LINE DIAGRAM OF 2 STAGES WITH INTERCOOLING

V1: Close V4: Open V7: Close

V2: Close V6: Open

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 LINE DIAGRAM OF 2 STAGES WITHOUT INTERCOOLING

V1: Close V4: Open V7: Close

V2: Close V6: Close

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LINE DIAGRAM OF SINGLE STAGE WITH LP CYLINDER

V1: Open V4: Close

V2: Close V7: Open

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LINE DIAGRAM OF SINGLE STAGE WITH HP CYLINDER

V1: Open V4: Close

V2: Open V7: Close

V3: Close

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4 SAFETY PRECAUTIONS:

• Always isolate the equipment from the electrical supply when carrying out
maintenance on the equipment.
• Ensure that safety notices are placed on the equipment supply advising personnel that
the equipment is being worked on, inspected and should not be operated.
• Injury would occur to the operational staff of the equipment through misuse, electric
shock, rotating equipment hazards and lack of cleanliness.
• Ensure that the person who works on the equipment is a qualified who is competent
in the safety aspects and operational mode of the equipment.
• The water should be at temperature under 35°C to maintain effectiveness.

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