FPE.

001

TWO STAGE RECIPROCATING AIR COMPRESSOR TEST RIG

Aim of the Experiment: To determine the volumetric efficiency and isothermal efficiencies of two stage reciprocating air compressor at various delivery pressures. Introduction and Theory The two stage reciprocating compressor consists of a cylinder, piston, inlet and exit valves which is powered by a motor. Air is sucked from atmosphere and compressed in the first cylinder (Low pressure) and passed to the second cylinder (High pressure) through an inter cooler. In the second cylinder, air is compressed to high pressure and stored in the air tank. During the downward motion of the piston, the pressure inside the cylinder drops below the atmospheric pressure and the inlet valve is opened due to the pressure difference. Air enters into the cylinder till the piston reaches the bottom dead center and as the piston starts moving upwards, the inlet valve is closed and the pressure starts increasing continuously until the pressure inside the cylinder above the pressure of the delivery side which is connected to the receiver tank. Then the delivery valve opens and air is delivered to the air tank till the TDC is reached. At the end of the delivery stroke a small volume of high pressure air is left in the clearance volume. Air at high pressure in the clearance volume starts expanding as the piston starts moving downwards up to the atmospheric pressure and falls below as piston moves downward. Thus the cycle is repeated. The suction, compression and delivery of air take place in two strokes / one revolution of the crank Apparatus Description The two-stage air compressor consists of two cylinders of v type. The compressor is driven by an AC motor. Air is first sucked into the low pressure (LP) cylinder and it is compressed and delivered at some intermediate pressure. The compressed air is then cooled in the intercooler and the same is then sucked by the high pressure (HP) cylinder. Compressed air is the finally discharged to the receiver tank. An orifice plate is mounted on one side of the air tank and which is connected with a manometer for the measurement of air flow rate. One side of the air tank is attached with a flexible rubber sheet to prevent damage due to pulsating air flow. A pressure gauge is mounted on the air tank to measure the air tank pressure. The tank pressure can be regulated by adjusting the delivery valve. A pressure switch is mounted on the air tank to switch off the motor power supply

automatically when the pressure inside the tank raises to the higher limit and to avoids explosion. Compressor Type: Two Stage Two Cylinder with finned intercooler L.P Cylinder: 76 mm bore Dia Stroke 127 mm Motor: 3 HP; 3 phase Max Working Pressure: 10 kg/cm2

Experimental Procedure 1. 2. 3. 4. 5. 6. Ensure that there is sufficient oil in the crank case of the compressor Fill the manometer with water up to half level. Keep delivery valve in closed position. Start the compressor and allow it to get stabilized. Maintain pressure of air inside receiver constant, by adjusting delivery valve. With delivery pressure constant, measure motor speed using tachometer and note it down. 7. With the same delivery pressure, note in the observation table intake temperature, intermediate temperature, intermediate pressure, delivery temperature, water manometer readings and delivery pressure. 8. Repeat the same procedure for the different numerical values of delivery pressures. Observation Table:
Sr. No. Speed (rpm) Manometer Reading hw (m) Time for 10 Impulse of Energy meter Suction Condition
P1 (kg/cm2) T1 (C)

After Stage 1st of Compressor

P2 (kg/cm2) T2 (C)

After Intercooling
P3 (kg/cm2) T3 (C)

Delivery Condition
P4 (kg/cm2) T4 (C)

CALCULATION

1) Air Flow Rate : (Free Air Delivery) Qa = Cd * A * V Where, A = Area of Orifice meter (Dia 10mm) = m2 V = Velocity of Air = ( 2 g h a ) Cd=Co-efficient of Discharge for given orifice meter 0.64 Now, ha= hw*w a hw = Diff in Water Manometer a = 1.293 * 273 = kg/m3 (273 + T1) Since Density of Air at 273 K is 1.293 kg/m3 Qa = Cd*A* ( 2 g h w * w ) a = m 3 /sec

2) Volumetric Efficiency: vol = Free Air Delivered in m 3 /sec Swept volume of Comp. Where, Swept Volume of Comp. = *D2 *L* N 4 60 = Where, D = Bore Dia. 76 mm L = Stroke Length 127 mm N = Sped of comp. in rpm m3 / sec

3) Isothermal Efficiency: = Isothermal work done Actual work done Abs. Pressure of Before 1st stage Comp. P1 = 1.01325 * 10 5 N / m2 st Abs. Pre. after 1 stage,P 2 = _____* 9.81 *10 4 + 1.01325 * 10 5 N / m

Abs. Pre. Before 2nd stage,P3 = _____* 9.81 *10 4 + 1.01325 * 10 5 N / m 2 Abs. Pre. after 2nd stage,P4 = _____* 9.81 *10 4 + 1.01325 * 10 5 N / m 2 Isothermal Work done = P1 V1 In (P4/P1) = watts V1 = Air Flow rate at Intake (Qa) in m3/sec

Actual .work done :- 10 * 3.6 * 106 * 0.75 K * t Where, K = Energy meter constant = 1600 imp/kwH t = Time for 10 impulse of Energy meter Motor Efficiency is 0.75

4) Poly Tropic Index,(n) For First stage, T1/T2 = (P2/ P1)n-1/n For Second Stage, T3/T4 = (P4 /P3)n-1/n 5) Compression Ratio First Stage Compression Ratio r1 = P2/P1 Second Stage Compression Ratio r2 = P4/P3 Overall Compression Ratio r = P4/P1 Graphs:Plot the for Comp. Ratio versus Vol. Efficiency Comp. Ratio versus Iso. Efficiency Result Table:Sr. No. Delivery Pressure First Stage Compression Ratio r1 Second Stage Compression Ration r2 Overall Compression Ratio r Volumetric Efficiency Isothermal Efficiency

SAMPLE READINGS

Observation Table:
Sr. No. Speed (rpm) Manometer Reading hw (m) Time for 10 Impulse of Energy meter 15 Suction Condition P1 (Atm) 1.01325 T1 (C) 30 After Stage 1st of Compressor P2 T2 (kg/cm2) (C) 1.6 94 After Intercooling P3 (kg/cm2) 2 T3 (C) 56 Delivery Condition P4 (kg/cm2) 7 T4 (C) 94

525

0.06

CALCULATION 1) Air Flow Rate : (Free Air Delivery) A = Area of Orifice meter (Dia 10mm) = 3.15 x 10-5 m2 a = 1.293 * 273 (273 + T1) a = 1.293 * 273 (273 + 30) Now, ha= hw*w a = 1.1649 kg/m3

= 0.06*1000 1.1649

= 51.503

Qa = C d * A * ( 2 g h a ) Here Cd=Co-efficient of Discharge for given orifice meter 0.64 = 1.59 x 10 -3 m 3 /sec

2) Volumetric Efficiency: Where, Swept Volume of Comp. = *D2 *L* N 4 60 = 5.04 x 10-3 m3/sec Where, D = Bore Dia. 76 mm L = Stroke Length 127 mm

N = Sped of comp. in rpm = 525 vol = Free Air Delivered in m 3/sec = 0.3169 or 31.69% Swept volume of Comp. 3) Isothermal Efficiency:Abs. Pressure of Before 1st stage Comp. P1 = 1.01325 * 10 5 N / m2 Abs. Pre. after 1 st stage,P 2 = 1.6 * 9.81 *10 4 + 1.01325 * 10 5 = 258285 N / m 2 nd Abs. Pre. Before 2 stage,P3 = 2* 9.81 *10 4 + 1.01325 * 10 5 = 297525 N / m 2 Abs. Pre. after 2nd stage,P4 = 7* 9.81 *10 4 + 1.01325 * 10 5 = 788025 N / m 2 Isothermal Work done = P1 V1 Ln (P4/P1) = 331.924 watts Here V1 = Air Flow Rate = 1.59 x 10 -3 m 3 /sec Actual .work done :- 10 * 3.6 * 106 * 0.75 K * t Where, K = Energy meter constant = 1600 imp/kwH t = Time for 10 impulse of Energy meter Motor Efficiency is 0.75

Actual .work done :- 10 * 3.6 * 106 * 0.75 = 1125 1600 * 15 = Isothermal work done = 0.295 or 29.5% Actual work done 4) Poly Tropic Index,(n) For First stage, T1/T2 = (P2/ P1)n-1/n Putting Values solving Equation n = 0.83 (approx.) For Second Stage, T3/T4 = (P4 /P3)n-1/n

Putting Values solving Equation n = 0.9 (approx.) 5) Compression Ratio First Stage Compression Ratio r1 = P2/P1 = 2.54 Second Stage Compression Ratio r2 = P4/P3 = 2.64 Overall Compression Ratio r = P4/P1 = 7.77
Sr. No. 1 Delivery Pressure 7 kg/cm2 First Stage Compression Ratio r1 2.54 Second Stage Compression Ration r2 2.64 Overall Compression Ratio r 7.77 Volumetric Efficiency 31.69% Isothermal Efficiency 29.5%