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Compressor
Exercise No 11
Introduction
Objective of the exercise is to investigate thermodynamic processes occurring in a reciprocating
compressor, determine key components of its energy balance and compare obtained results with
theoretical description.
In an ideal reciprocating compressor the compression process is isothermal. In such a process the
work needed to compress gas would be minimal. Real compressors however do not work that way;
compression process is polytropic, almost adiabatic. This results with increased energy consumption
and increased outlet gas temperature, which may cause some problems. This is one of the reasons of
utilising multi-stage compressors with intercooling. Intercooling allows to decrease final gas
temperature (and also its final volume), decrease dimensions of further stages and lower work
needed for entire compression process. Figure below shows theoretical single-stage compression in
a reciprocating compressor.
1-2 is the actual compression process, 3-2 is gas removal from the cylinder, 3-4 is decompression of
remaining gas (there is always some gas remaining after the outlet valve is closed) and 4-1 is supply
of another batch of low pressure gas.
Area inside the curve reflects the work theoretically needed to complete entire compression cycle.
Processes 2-3 and 4-1 are not isobaric, there are visible pressure variations near points 2 and
4 related to valve opening
Compression/expansion processes are not adiabatic.
Due to those facts the actual work (indicated work) is higher than theoretical value for the same
pressure difference and volume.
Investigated machinery
The investigated piece of equipment is a low-speed two-stage reciprocating compressor with both
pistons installed on common connecting rod, driven by a three-phase AC electric motor via belt
transmission system. The ambient air is sucked into the 1st stage, compressed there, then cooled in
an intercooler and further compressed with the 2nd stage, which has additional jacket cooling. From
the 2nd stage the air is directed to an equalising tank and then to a system of pipelines with flow
measurement devices installed.
The main dimensions of the compressor are:
Stroke s = 0.15 m
Both intercooler and 2nd stage jacket are cooled with water (parallel connection on the water side).
There are following measurements:
Motor voltage
Motor current
Motor power (currently unserviceable, use power factor value from the motors plate)
Speed
Air pressure after 1st stage
Air pressure after 2nd stage
Inlet water temperature
Intercooler outlet water temperature
Jacket outlet water temperature
Intercooler water flow
Jacket water flow.
The compressor is also equipped with an indicator a mechanical device which draws p-V diagrams
for both stages.
Flow measurement
Flow measurement may be calculated according to the displacement volume and number of cycles in
a unit of time (speed):
D1 n s
V
s
4
2
Stroke
Speed
where : D1
s V
m
0
The air density shall be calculated for measured ambient conditions, using ideal gas law and
gas constant of R = 287 J/(kg K).
Flow in the pipeline downstream from the compressed air tank may be measured with measurement
nozzle:
K d2
m
where: d
p
p
v
empirical coefficient.
K = 1.15292967
While both values should be identical (in a steady state and with valves at the pipeline open, i.e.
when the flows into the tank and from the tank are equal), but there will be a noticeable difference.
This is primarily caused by:
Fact that the piston never actually reaches cylinder head, so some of the compressed air is
not pushed out of the cylinder, but gets expanded instead (see Vs on charts above)
pi
where: F
la
After average indicated pressure is determined for each stage, indicated power Ni may be calculated
as:
NI
n s
2
2
D1 pi1 pi2 D2 pi2
4
D2
stroke
speed
pi1
pi2
where: D1
Nel U I 3 cos
where cos = 0.86.
Compressor shaft power is therefore:
N s Ne m t
where: m
transmission efficiency
t = 0. 97
Ni
Ns
m
w 1 c w (t w 2 t w 1 ) m
w 2 c w (t w 3 t w 1 )
Q
w
where:
w1
m
w2
m
t w1
t w2
t w3
cw
c w = 4.19 kJ/(kg K)
Report
The report should contain measurement results, calculation of individual energy balance components
and conclusions. Detailed information will be provided by the instructor.