RECIPROCATING

COMPRESSOR
 CONTENT
• Working Cycle and p-v Diagram
• Indicated Power and work
• Conditions for minimum work
• Mechanical Efficiency
• Isothermal Efficiency
• Clearance Volume
• Volumetric Efficiency
• Multistage Compressor 2
 What is Compressor?
 Compressors uses mechanical work to take an
amount of fluid and deliver it at a required
pressure
 An efficient compressor increases pressure
with minimum work
 The amount of fluid is limited by the volume
of the compressor cylinder which is fixed
 The reciprocating compressor operates in a
cyclic manner
 The properties of the working fluid at inlet
and outlet are average values 3
 CLASSIFICATION
COMPRESSOR

INTERMITTENT FLOW CONTINOUS FLOW

POSTIVE DISPLACEMNT DYNAMIC EJECTOR

ROTARY RECIPROCATING RADIAL MIXED AXIAL

FLOW FLOW FLOW

SLIDING VANE MECHANICAL

LIQUID PISTON PISTON CENTRIFUGAL MIXED AXIAL
FLOW
HELICAL LOBE
SCREW
LOBED BLOWER
 Reciprocating Compressor
 In a reciprocating compressor, a volume of gas is
drawn into a cylinder, it is trapped, and
compressed by piston and then discharged into
the discharge line. The cylinder valves control the
flow of gas through the cylinder; these valves act
as check valves. There are two types of
reciprocating compressor.
 Reciprocating Compressor
Types
 Single – Acting compressor
It is a compressor that has one discharge per
revolution of crankshaft.
 Double – Acting Compressor
It is a compressor that completes two discharge
strokes per revolutions of crankshaft. Most heavy-
duty compressors are double acting..
 Basic Components of a
Reciprocating Compressor
 A compressor consist of:
Outlet Inlet
 crank case encloses the
compression volume Delivery
valve
Induction
valve
 crank shaft rotates the crank
Piston
 piston moves through the cylinder
during each cycle
Connecting
 crank and connecting rod rod
connects the crank with the piston
Crank
 spring loaded induction and delivery
valves
 cylinder where piston travels
Crank
 The crank shaft is usually driven case

by an electric motor Schematic Layout

7
 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
p2 b
 Temperature also increases

 (b – c): Delivery
 Delivery valve opens
 High pressure air is delivered
 Pressure and temperature is constant
during this process p1 d a

Compression process is reversible polytropic e f v

 0
and follows the law pVn = C 8
 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
 Work for polytropic process is given by:

p2v 2  p1v 1
Win 
1 n
where
n  polytropic index of a gas

9
 WORK & INDICATED
POWER
 Work input per cycle p
Win  area abcd
cycle
P2 c b
 area abef  area bc0e  area ad0f
 p V  p1Va   p V  p V
 2 b 2 b 1 a
n 1
p V  p1v a  (n  1) p 2v b  (n  1) p1v a
 2 b
n 1 P1 d a
n
  p 2Vb  p1Va  V
n 1 0 e f

Since p1V a  mRT 1 and p 2V b  mRT 2 Indicated Power

So, work input per cycle n 
IP  m R T 2  T 1 
Win n n 1
cycle
  mRT 2  mRT 1  where m  N  m and
n 1
n N  R.p.m
 mR T 2  T 1 
n 1
10
 Example
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

11
 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

12
 CONDITIONS FOR MINIMUM
WORK
 pV =constant (isothermal)
p
 pV =constant (isentropic) b1 b b2
 pVn =constant (polytropic) P2 c
pV = C
pVn = C
 From here it can be seen
pV = C
that the isothermal process
is the best because it
requires minimum work P1 d a

 So it is best that the gas 0 e f

temperature is constant v2 v1 V
throughout the compression
cycle

13
 CONDITIONS FOR MINIMUM
WORK
ISOTHERMAL WORK p
Work  area ab1ef  area b1c0e - area ad0f b1
P2 c
p1
 p2Vb1 ln  p1Vb1  p1Va
p2
pV = C
for isothermal process p1Va  p2Vb
p1 p1
Win  p2Vb1 ln  p1Va ln
p2 p2
From pV  mRT P1 d a
p
Win  mRT ln 1
p2 0 e f
where T is the constant temperature V
p
Isothermal power  m RT ln 2
p1

14
 CONDITIONS FOR MINIMUM
WORK
ISOTHERMAL EFFICIENCY
 Isothermal efficiency indicates isothermal work compared to the
indicated work.
Isothermal Work
Isothermal Efficiency ,isoth 
Indicated Work

15
 EXAMPLE
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

16
 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

17
 MECHANICAL EFFICIENCY,
ηm

Power system Compressor

[Power required] > [Indicated power]

• 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

18
 Example
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.
The compressor is to be driven at 300 rev/min and is a single acting,
single cylinder machine, Calculate:
i. Mass of air delivered per minute
ii. Indicated power
iii. The cylinder bore required, assuming a stroke to bore
ratio of 1.5/1
iv. The power of the motor required to drive the compressor
if the mechanical efficiency of the compressor is 85% and
that of the motor transmission is 90%

19
 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

20
 CLEARANCE VOLUME (VC)

 Process P
 After delivery at (c) (volume is VC, e c b
p2
pressure is p2 and temperature is
PVn = C
T2). So, there are some gas left in
the cylinder PVn = C
 When piston moves downward, this
gas expands according to PVn = C
until p1 at (d). p1
f d a
 Then induction begins (d – a)
 Then gas is compressed according v
VC VS
to PVn = C
 Finally there is the delivery (b – c) VC = Clearance volume
VS = Swept volume

21
 Effect of VC
 Because of the expansion of gas
remaining in the VC, induced P
volume is reduced from swept p2
e c b
volume VS to (Va – Vd) which is
PVn = C
the effective volume
PVn = C
V  Va  Vd or V  Va  Vd
 Mass or air per unit time p1
f d a
m a  m b and m c  m d
VC VS v
 Mass delivered per unit time =
mass induced per unit time

 m
m  b m
c m
 a m
d
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 CLEARANCE VOLUME (VC)
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  ma R T 2  T 1   md R T 2  T 1 
n 1 n 1
n
  m a  m d R T 2  T1 
n 1
P
because m a  m d  m  mass induc ed per unit time 
e c b
 n 1
 p2
n  n   p  n
W  mR T 2  T 1   
mRT 1  2
 1
n 1 n 1  p  PVn = C
 1  
 kg 
where m  N  m   PVn = C
 min 
 kg 
or m  N   ma  md   
 min 
p1
 We see here that the work done per cycle and f d a
indicated power per unit mass is the same whether
23 v
with or without clearance VC VS
 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

24
 EXAMPLE
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

25
 EXAMPLE
A single stage, single-acting compressor running at 1000
rev/min deliver air at 25 bar. For this purpose the induction
and free air conditions can be taken as 1.013 bar and 15oC,
and the FAD as 0.25m3/min. The clearance volume is 3% of
swept volume and the compression index is 1.3. and the
stroke/bore ratio is 1.2/1. Calculate
i. Bore and stroke size
ii. Volumetric efficiency

iii. Indicated power

iv. Isothermal efficiency

26
 VOLUMETRIC EFFICIENCY, ηv

 Volumetric efficiency is another definition to measure the

performance of a compressor.
 The are two ways how to define volumetric efficiency:
 1st definition:
 The ratio of the actual induced mass (mactual) in the
cylinder with ideal induced mass at free air condition (mideal).
Free air condition is basically the ambient condition
P1 Va Vd  PoV s
mactual   and mideal 
RT 1 RT o

 Where Po is the ambient pressure

To is the ambient temperature

27
 VOLUMETRIC EFFICIENCY, ηv
 So by first definition,
P
P1 Va Vd  e c b
RT 1 P V Vd  RT 0 p2
v   1 a 
P0V s RT 1 P0V s PVn = C
RT 0
PVn = C

v 
Va Vd   P1  T 0
Vs P0 T1
p1
 If assume P1  Po and T 1  T o , v
V Vd 
 a
f d a

Vs
VC VS v
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)
V s  Vc  V s V c 
28
 VOLUMETRIC EFFICIENCY, ηv
n n
 Since P1Vd  P2Vc
1
n
Vd  P Vd  P2  n
   2 and therefore   
V c  P1 Vc  P1 

 Insert the above equation to equation (1) and we get

 1

Vc   P2  n 
v  1      1 
V s   P1  
 
 NOTE:
 The above equation is only true when Po=P1 and To=T1

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)

Vactual  at free air condition

v 
Vs
We know that actual mass induced is
P1 Va Vd 
mactual 
RT 1

If we measure actual mass induced at free air condition, it will be

Po V actual 
mactual 
RT o

30
 VOLUMETRIC EFFICIENCY, ηv
 Combining the two mathematical definition, we get

Po Vactual  P1 V a Vd 

RT o RT 1
P1 T 0
Vactual  Va Vd    (1)
P0 T 1

 Insert equation (1) into v  Vactual  at free air condition

Vs

v 
Va Vd   P1  T 0
Vs P0 T1
 Note that the equation above is the same the one in the first
definition.

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 Example
A single stage, double-acting air compressor has a
FAD of 14 m3/min measured at pressure of 1.013 bar
and 15°C. The pressure and temperature in the
cylincer during induction are 0.95 bar and 32°C. The
delivery pressure is 7 bar and the index of
compression and expansion is 1.3. The clearance
volume is 5% of swept volume. Calculate:
i. Indicated power
ii. Volumetric efficiency
iii. Swept volume
32
 MULTI-STAGING COMPRESSOR
• When delivery pressure is
increased to a higher value,
P
several weaknesses were
found: p4 c” b”

1. Induce volume will be less

2. Increase in delivery c’ b’
p3
temperature
3. Decrease of volumetric
efficiency (FAD become less
were else no change in Vs) p2 c b

p1
• To overcome those matter, d d’ d” a
multi-staging compressor is
V
introduced VC VS

33
 MULTI-STAGING COMPRESSOR
Coolant in Coolant out

P1,Ta Pi,Tb Pi,Ta P2,Tc

Intercooler
LP Compressor HP 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
34
index.
 MULTI-STAGING COMPRESSOR
a-b : PVn=C compression p

g
b-e : Q from air to surrounding P2 f

Temperature drops from Tb to Te. Ideally HP

Te=Ta CPMPRESSOR

e-f : PVn=C compression

c h b
Pi
Advantages: e

a. Slight increase in temperature LP CPMPRESSOR

b. Increase in volumetric efficiency

c. Saving in work ( shaded area)
P1 a
d

V
Vc Vs
***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. 35
 EXAMPLE
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.

36